Machine and method for attaching casing to a structural frame assembly

ABSTRACT

A machine and method for semi-automatically attaching casing to a structural frame assembly is provided. The machine includes a support frame assembly, a fixed bank of stapling units supported by the support frame assembly, a movable bank of stapling units slidably supported by the support frame assembly and oriented substantially parallel to the fixed bank, and a head bank of stapling units located at one end of the fixed and movable banks and also supported by the support frame assembly. Each bank of stapling units includes a pivot bar, stapling units attached to the pivot bar for stapling the casing to the structural frame assembly, and clamping assemblies attached to the pivot bar for positioning and clamping the casing adjacent the structural frame assembly. The fixed and movable banks include jamb locators which are positioned to engage and retain the longitudinal edges of the structural frame assembly. The structural frame assembly is received between the jamb locators with the pivot bars in the up position. Casing is placed in the clamping assemblies. The pivot bars are rotated to place the casing in abutment with the structural frame assembly and the stapling units adjacent the casing. The stapling units are activated to staple the casing to the structural frame assembly. The pivot bars are rotated back to their starting position, lifting the stapling units and clamping assemblies away from the structural frame assembly.

FIELD OF THE INVENTION

This invention relates to machines for and methods of semi-automaticallyattaching casing or molding to a structural frame assembly, such as apre-hung door assembly. More particularly, this invention relates tomachines for and methods of attaching casing to a structural frameassembly wherein the structural assembly is received and retained by amachine, the casing properly positioned on the structural frame assemblyby the machine and fasteners such as staples driven through the casingby the machine into the structural frame assembly to securely attach thecasing to the frame assembly.

BACKGROUND OF THE INVENTION

Prior to the development of pre-hung door assemblies, door assemblies inhome and commercial construction and reconstruction were constructed atthe job site, in the respective doorways. That is, the individualelements comprising the assembly were received at the job site and thedoor assembly was completely constructed at the job site.

Thereafter, beginning in the late 1950's and early 1960's, the use ofpre-hung door assemblies became prevalent. Pre-hung door assemblies aredoors and jambs which are assembled in the factory (i.e. the jambs areattached and the door is attached to the assembled jambs) and shipped toretail outlets through distribution channels as complete units orassemblies. Such pre-hung doors assemblies are then installed in theframing forming the doorways. The casing or molding is attached to thejambs on the job site after the pre-hung door assemblies are affixed tothe framing.

The development of such pre-hung door assemblies was an advance inbuilding construction technology and provided many benefits over theprior method of constructing door assemblies entirely at the job site.Among these benefits are that, due to the fact that the pre-hung doorassemblies are constructed at a manufacturing site by persons who becomeskilled at the task, the pre-hung door units are generally of higherquality and are consistently of the same dimensions. In addition, theuse of such pre-hung door assemblies decreases the labor time on the jobsite. Moreover, such pre-hung door assemblies can be installed by almostall workers, as the installation does not require a person of greatskill and experience.

However, even when employing these pre-hung door assemblies, the casingmust still be properly positioned on and attached to the respective doorjambs after the pre-hung door assemblies are installed at the job site.This task requires skilled labor and is time consuming. Thus, while theuse of pre-hung door assemblies including the jambs and the doors solvesome problems in the field, problems remain in attaching the casing oncethe pre-hung door assemblies are installed.

One solution to this problem is to manually attach the casing in thefactory. However, this is a time consuming process in the factory andincreases the cost of the pre-hung door assemblies since the factorynormally employs workers of a higher skill and compensation level thanin the field. Furthermore, consistency is still a problem since thequality of the attachment is dependant on the skill level andperformance of the person performing the task. Further, there is somerisk of injury during this manual attachment.

Thus, there is a need for a machine and a method for semi-automaticallyattaching casing to pre-hung door assemblies. Such a machine and methodmay have applications beyond pre-hung door assemblies, and may beemployed to attach molding or casing to other structural frame elements.

There is one known prior patent which discloses a machine forautomatically nailing trim on door jambs, see U.S. Pat. No. 2,830,294issued to Guerrant on Apr. 15, 1958. However, the machine disclosed inthis patent is cumbersome and inefficient.

There are other patents which disclose machines and methods forassembling pre-hung doors with casing, see U.S. Pat. No. 3,015,348issued to Zern on Jan. 2, 1962, U.S. Pat. No. 3,252,642 issued to Pageon May 24, 1966 and U.S. Pat. No. 3,707,256 issued to Lubin on Dec. 26,1972. The machines disclosed in these patents are also unduly cumbersomeand inefficient.

Other known patents disclose machines and methods for automatically orsemi-automatically assembling structural frame units, see U.S. Pat. No.2,903,699 issued to Mazzola on Sep. 15, 1959, U.S. Pat. No. 2,936,457issued to Chafin et al. on May 17, 1960, U.S. Pat. No. 3,261,527 issuedto Sterner on Jul. 19, 1966, U.S. Pat. No. 3,278,177 issued to Zern onOct. 11, 1966, U.S. Pat. No. 3,431,619 issued to Bowers, Jr. on Mar. 11,1969, U.S. Pat. No. 3,628,714 issued to Offenwanger on Dec. 21, 1971,U.S. Pat. No. 3,672,554 issued to Smith on Jun. 27, 1972, U.S. Pat. No.3,681,842 issued to Blakeslee on Aug. 8, 1972, U.S. Pat. No. 3,733,020issued to Ingram on May 15, 1973, U.S. Pat. No. 3,822,815 issued toDavis on Jul. 9, 1974, U.S. Pat. No. 3,873,015 issued to Whitaker onMar. 25, 1975, U.S. Pat. No. 4,039,112 issued to Schultz on Aug. 2,1977, U.S. Pat. No. 4,126,259 issued to Galer et al on Nov. 21, 1978,U.S. Pat. No. 4,127,226 issued to Jasper on Nov. 28, 1978, U.S. Pat. No.4,254,895 issued to Cheak on Mar. 10, 1981, U.S. Pat. No. 4,258,873issued to Vela on Mar. 31, 1981, U.S. Pat. No. 4,305,538 issued toSchultz et al. on Dec. 15, 1981, U.S. Pat. No. 4,330,921 issued toWhite, Jr. on May 25, 1982, U.S. Pat. No. 4,392,599 issued to Russell onJul. 12, 1983 and U.S. Pat. No. 4,436,234 issued to Kennedy on Mar. 13,1984. In addition, U.S. Pat. No. 3,112,105 issued to Keller on Nov. 26,1963 and U.S. Pat. No. 3,559,863 issued to Sack on Feb. 2, 1971 disclosedevices for assembling furniture and U.S. Pat. No. 3,502,256 issued toBoulay et al. on Mar. 24, 1970 discloses an apparatus for closing andstapling cartons.

None of these prior machines or methods provide a machine or method forconsistently, quickly and accurately positioning casing in a properposition relative a door jamb assembly or pre-hung door assembly andautomatically fastening the casing to the door jamb assembly or pre-hungdoor assembly. Furthermore, use of the prior machines or methods doesnot result in a high quality work product.

Thus, there still exists a need in the technology for a machine andmethod for attaching casing to a pre-hung door assembly, or otherstructural frame assembly, which is quick, efficient, accurate andresults in a high quality work piece. The machines and methods of thisinvention fulfill this need, as discussed below.

SUMMARY OF THE INVENTION

This invention provides a machine for attaching casing to a structuralframe assembly, the machine including a support frame assembly, a fixedbank of stapling units, a movable bank of stapling units, a head bank ofstapling units and mechanisms for controlling, activating andcoordinating the various subassemblies of the machine.

The fixed bank of stapling units is supported by the support frameassembly and includes a first pivot bar, stapling units, clampingmechanisms and a first jamb locator. The first pivot bar is rotatablysupported by the support frame assembly. The stapling units are attachedto the first pivot bar, and when properly operated, drive staples toattach the casing to the structural frame assembly. The clampingmechanisms are also attached to the pivot bar and are designed toreceive casing and position and clamp the casing adjacent the structuralframe assembly during the stapling of the casing to the structural frameassembly. The jamb locator is fixedly supported by the support frameassembly.

The movable bank of stapling units is spaced from and orientedsubstantially parallel to the fixed bank of stapling units and includessupport bars slidably supported by the support frame assembly, a secondpivot bar, a second jamb locator, stapling units, clamping mechanismsand a mechanism for sliding the support bars relative the support frameassembly. The second pivot bar is rotatably supported by the supportbars. The second jamb locator is fixedly supported by the support bars.The stapling units and clamping mechanisms are attached to the secondpivot bar and function to drive staples to attach the casing to thestructural frame assembly and to position and clamp the casing adjacentthe structural frame assembly during the stapling of the casing to thestructural frame assembly.

The head bank of stapling units is located at one end of the fixed andmovable banks of stapling units and includes a third pivot bar rotatablysupported by the support frame assembly and a stapling unit and clampingmechanisms attached to the third pivot bar. The stapling unit andclamping mechanisms function in the same manner as the stapling unitsand clamping mechanisms of the fixed and movable banks of staplingunits.

The jamb locators are designed to receive and engage the structuralframe assembly between them when the structural frame assembly is in theposition to have the casing attached thereto.

In some embodiments of this invention, the machine includes cornersplicing assemblies which are located at the corners formed by (1) thefixed bank and the head bank of stapling units and (2) the movable bankand the head bank of stapling units. These assemblies drive splines intothe corners formed by the individual casing pieces when the casing isproperly positioned relative the structural frame assembly.

In other embodiments, the machine includes mechanisms for transportingthe structural frame assembly from a position outside of the machine toa position adjacent the fixed bank and for moving the structural frameassembly away from the fixed bank.

Other embodiments of this invention include mechanisms for rotating thepivot bars such that the clamping mechanisms and stapling units have upand down positions. The clamping mechanisms may be designed to receivecasing when in the up position and to position the casing against thestructural frame assembly when in the down position. The anvils of thestapling units are spaced the farthest from the casing when the staplingunits are in the up position, and moved closer to the casing when thestapling units are in the down position.

In yet other embodiments, each of the clamping mechanisms and staplingunits may include mechanisms for rotating the clamping mechanisms andstapling units relative the pivot bars. These mechanisms may function toapply additional clamping pressure on the casing and structural frameassembly and to position the anvils of the stapling units in contactwith the casing.

This invention also includes a method of attaching casing to astructural frame assembly utilizing the machine described above andincluding the following steps.

The clamping mechanisms and stapling units are positioned in their uppositions and the movable bank is positioned in its out position. Casingis placed in the clamping mechanisms.

The structural frame assembly is conveyed to a position such that thestructural frame assembly is at the same elevation as the jamb locatorsand a longitudinal side of the structural frame assembly is adjacent thejamb locator of the fixed bank of stapling units. The movable bank ofstapling units is then slid relative the support frame assembly untilthe jamb locators of the fixed and movable banks are in abutment withthe longitudinal sides of the structural frame assembly. The pivot barsof the fixed bank, movable bank and head bank of stapling units arerotated and the rotating mechanisms of the clamping assemblies andstapling units are operated until the casing is clamped in abutment withthe structural frame assembly and the anvils of the stapling units arein contact with the casing.

The stapling units are activated to drive staples through the casing andinto the structural frame assembly. The corner splicing assemblies areactivated to drive splines into the corners of the casing. The rotatingmechanisms of the stapling units and clamping assemblies are operated tolift the stapling units away from the casing and such that the clampingassemblies disengage the casing. The pivot bars of the fixed bank,movable bank and head bank of stapling units are rotated to move theclamping mechanisms and the stapling units further away from the casing.Finally, the movable bank of stapling units is moved away from thestructural frame assembly and the structural frame assembly is removedfrom the machine.

In some embodiments of this invention, the fixed bank and movable bankof stapling units each include end positioning units which are locatedat the ends of the fixed and movable banks of stapling units oppositethe head bank of stapling units. The positioning units engage the casingand the structural frame assembly when the casing is placed in abutmentwith the structural frame assembly to properly align the casinglongitudinally relative the structural frame assembly. The endpositioning units may include top and bottom extendable and retractablearms, with the arms being oriented parallel to the jamb locators of thefixed and movable bank of stapling units. The top arms may be positionedto engage the casing and the bottom arms may be positioned to engage thestructural frame assembly when the casing is in abutment with thestructural frame assembly.

The fixed, movable and head banks of stapling units of other embodimentsof this invention may include a plurality of spaced clamping mechanismsand stapling units.

In further embodiments of this invention, the stapling unit of the headbank of stapling units is slidably supported by the third pivot bar. Themechanism for controlling the head stapling unit may operate to move thehead stapling unit along the third pivot bar and to stop and activatethe head stapling unit at fixed intervals along the third pivot bar,thus driving staples into the casing at the fixed intervals.

In yet other embodiments of this invention, the mechanism for moving andpositioning the structural frame assembly includes a mechanism forlifting and lowering the structural frame assembly within the supportframe assembly.

In other embodiments of this invention, the stapling units of themovable bank and the stapling units of the fixed bank are aligned inparallel straight lines.

The machines and methods of this invention have many advantages over theprior machines for and methods of constructing structural frame elementshaving casing or attaching casing to a pre-constructed structural frameassembly.

These advantages include that employment of a machine and/or a method inaccordance with this invention results in an end product, i.e., casingattached to a structural frame assembly, of a higher quality than can beachieved with prior methods and machines.

In addition, the machines and methods according to this inventionprovide a quicker method for attaching casing to a structural frameassembly than prior machines and methods.

Further, use of a machine and/or a method in accordance with thisinvention results in a more accurate assembly of the casing to thestructural frame assembly. For example, the corners of the casing are incorrect alignment and firmly attached, the desired reveal is providedfor, etc.

Furthermore, employment of methods and machines in accordance with thisinvention results in a more consistent end product.

Yet another advantage is that use of machines and methods in accordancewith this invention results in consistent stapling of the casings to thestructural frame assemblies. That is, the staples are driven in withsubstantially the same force, and at the same spacing, in each productproduced by the machines and methods.

Yet another advantage is that the machines and methods according to thisinvention are adaptable to receive structural frame assemblies andcasing of different sizes, including frames of different heights andwidths, casings of different widths and jambs of different widths. Thus,a single machine can be employed to attach different size casings ondifferent size structural frame assemblies. Moreover, the machinesaccording to this invention can be designed to accept door jambassemblies and casings built in accordance with the metric system, ormachines built for the United States measurement system can berelatively easily converted to handle door jamb assemblies built inaccordance with metric measurements.

Furthermore, because of the semi-automatic nature of the machines inaccordance with this invention, the risk of injury is greatly reduced.The persons operating the machines are not required to be in or aroundthe machine when the clamping and stapling process occurs. This greatlyreduces the risk of injury to those persons.

Another advantage of this invention is that employment of the machinesand methods in accordance with this invention greatly reduces the labortime, skill level and cost needed to attach casings to a structuralframe assembly. Essentially, technology is replacing steps in theconstruction industry previously conducted by manual labor.

A further advantage of this invention is that the stapling units of themachines can be oriented to drive the staples which fasten the casing tothe door jamb assembly in across the grain of the casing. Staples drivenin across the grain provide a more secure attachment of the casing tothe door jamb assembly than staples driven with the grain, i.e. suchstaples have a higher resistance to failure. Also, the risk of thecasing splintering during the attachment of the casing to the door jambassembly is greatly reduced by orienting the staples across the grain ofthe casing.

Other advantages and salient features of the invention will becomeapparent from this disclosure. Certain embodiments of this inventionwill now be described with respect to the drawings, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view, partially schematic, of a casing attachmentmachine in accordance with this invention.

FIG. 2 is a perspective view of the bottom support frame assembly of theembodiment of this invention illustrated in FIG. 1.

FIG. 3 is a partial perspective view of the bottom support frameassembly illustrated in FIG. 2, illustrating the bumper assembly and thespacer bar.

FIG. 4 is a partial perspective view of the fixed bank of stapling unitsof the embodiment illustrated in FIG. 1, illustrating the air cylinderassembly which rotates the pivot bar of the fixed bank.

FIG. 5 is a perspective view of an embodiment of the stapling unitassemblies of the fixed and movable banks of stapling unit assemblies ofthe embodiment of this invention illustrated in FIG. 1.

FIG. 6 is a top perspective view of the stapling unit assemblyillustrated in FIG. 5.

FIG. 7 is a plan view of the Z-bar which can be employed in the staplingunit assembly illustrated in FIGS. 5 and 6.

FIG. 8 is a side view of the Z-bar illustrated in FIG. 7.

FIG. 9 is a side view of an embodiment of the clamping assemblies of thefixed and movable banks of stapling unit assemblies of the embodiment ofthis invention illustrated in FIG. 1.

FIG. 10 is a partial end view of the clamping assembly illustrated inFIG. 9.

FIG. 11 is a partial top view of the clamping assembly illustrated inFIGS. 9 and 10.

FIG. 12 is a perspective view of an embodiment of the combined staplingand clamping unit assemblies of the fixed and movable banks of staplingunit assemblies of the embodiment of this invention illustrated in FIG.1.

FIG. 13 is a perspective view of an embodiment of the trim guide poleand end air cylinder assemblies, which align the casing and structuralframe assembly longitudinally in the casing attachment machine, of thefixed and movable banks of the embodiment of this invention illustratedin FIG. 1.

FIG. 14 is a perspective view of an embodiment of the slidable frameassembly of the movable bank of the embodiment of this inventionillustrated in FIG. 1.

FIG. 15 is a perspective view of the air cylinder assembly of themovable bank of the embodiment illustrated in FIG. 1 which rotates thepivot bar of the movable bank.

FIG. 16 is a perspective view of an embodiment of the air cylinderassembly which locks the movable frame to the bottom support frameassembly of the embodiment of this invention illustrated in FIG. 1.

FIG. 17 is a perspective view of an embodiment of the trim guideassembly and right side clamping assembly of the head bank of staplingunits of the embodiment of this invention illustrated in FIG. 1.

FIG. 18 is a perspective view of the clamping assembly illustrated inFIG. 17 and of an embodiment of the movable stapling unit of the headbank of the embodiment of this invention illustrated in FIG. 1.

FIG. 19 is a perspective view, partially cut away for clarity, of anembodiment of the left side clamping assembly and left side ejection aircylinder assembly of the head bank of the embodiment of this inventionillustrated in FIG. 1.

FIG. 20 is a front perspective view of the clamping assembly illustratedin FIG. 19, an embodiment of the stationary stapling unit assembly andan embodiment of the corner splicing assembly of the embodiment of thisinvention illustrated in FIG. 1.

FIG. 21 is a side perspective view of the clamping assembly illustratedin FIGS. 19 and 20.

FIG. 22 is a perspective view of an embodiment of the stationarystapling assemblies of the head bank of stapling units of the embodimentof this invention illustrated in FIG. 1.

FIG. 23 is a rear perspective view of the stationary stapling unitassembly illustrated in FIG. 22, an embodiment of the right sideclamping assembly and an embodiment of the movable stapling assembly ofthe head bank of stapling units of the embodiment of this inventionillustrated in FIG. 1.

FIG. 24 is a partial rear perspective view of the head bank of theembodiment of this invention illustrated in FIG. 1, illustrating the aircylinder assembly which rotates the pivot bar of the head bank.

FIG. 25 is a side perspective view of an embodiment of the cornersplicing assemblies of the embodiment of this invention illustrated inFIG. 1.

FIG. 26 is a partial top view of the embodiment of the corner splicingassembly illustrated in FIG. 25.

FIGS. 27A and 27B are partial side views of the embodiment of the cornersplicing assembly illustrated in FIGS. 25 and 26, illustrating thecorner splicing assembly in the retracted (FIG. 27A) and extended (FIG.27B) positions.

FIG. 28 is a rear perspective view of the embodiment of the cornersplicing assembly illustrated in FIGS. 25-27.

FIG. 29 is a top perspective view of the embodiment of the cornersplicing assembly illustrated in FIGS. 25-28, illustrating the clampingassembly in the down position.

FIG. 30 is a top perspective view of the embodiment of the cornersplicing assembly illustrated in FIGS. 25-29, illustrating the clampingassembly in the up position.

FIG. 31 is a partial perspective view of an embodiment of the assemblyfor lifting and lowering a structural frame assembly of the embodimentof this invention illustrated in FIG. 1.

FIG. 32 is a partial perspective view of the assembly for raising andlowering the structural frame assembly illustrated in FIG. 31,illustrating one of the support squares in the up position.

FIG. 33 is a block diagram illustrating an assembly line utilizing theembodiment of this invention illustrated in FIGS. 1-32.

FIG. 34 is a partial rear perspective view of the head bank of staplingunits of the embodiment of this invention illustrated in FIG. 1.

FIG. 35 is a partial perspective view, partially cut away for clarity,of the fixed bank of stapling units of the embodiment of this inventionillustrated in FIG. 1.

FIGS. 36A-F illustrate, partially in schematic, the steps of a method ofemploying the embodiment of this invention illustrated in FIGS. 1-32, 34and 35.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, in particular FIG. 1, a casing attachmentmachine is provided in accordance with this invention, casing attachmentmachine 20, which includes support frame assembly 22, fixed bank ofstapling units 24, movable bank of stapling units 26, head bank ofstapling units 28, corner splicing assemblies 30 and 32, liftingassembly 34 and conveyor belt assembly 36.

SUPPORT FRAME ASSEMBLY

Support frame assembly 22 is illustrated in detail in FIG. 2 andincludes longitudinal base members 39, 40 and 41, lateral base members42, 44, 46, 48, 50, 51 and 52, upright members 54, 56, 58, 60, 61, 62,64, 66 and 68, end support member 70, fixed bank support assembly 72,movable bank support assembly 74, head bank support beam 76 and diagonalsupport beams 78, 80, 82, 84, 86 and 88.

Fixed bank support assembly 72 includes longitudinal beam 90, lateralbeam 91, beam caps 92 and 94, beam extension 95, support plates 96 and98 and L-shaped members 100 and 102.

Movable bank support assembly 74 includes longitudinal beams 104 and105, lateral beams 106, 107 and 108, beam extension 110, rods 112 and113, rod supports 114-119, bumper assembly 109, spacer bar 111 andL-shaped members 101 and 103.

In this embodiment, longitudinal members 39, 40, 41, 90, 104 and 105,lateral members 42, 44, 46, 48, 50, 51, 52, 91, 106, 107 and 108, endsupport member 70, head bank support beam 76 and beam extensions 95 and110 are substantially horizontal and upright members 54, 56, 58, 60, 61,62, 64, 66 and 68 are substantially vertical.

Longitudinal base member 39 is connected at its ends to the lower endsof upright members 56 and 60. Longitudinal base member 40 is attached atits ends to the lower ends of upright members 62 and 66. Longitudinalbase member 41 is attached at its ends to the lower ends of uprightmembers 64 and 68.

Lateral base member 42 is connected on its ends to the lower ends ofupright members 54 and 56. Lateral base member 44 is attached on itsends to the lower ends of upright members 56 and 58. Lateral base member46 is attached at its ends to the lower ends of upright members 60 and62. Lateral base member 48 is attached on its ends to the lower ends ofupright member 58 and diagonal support beam 86. Lateral base member 50is attached on its ends to the lower ends of upright member 62 and 64.Lateral base member 51 is attached on its ends to the lower ends ofupright members 60 and 61. Lateral base member 52 is attached at itsends to the lower ends of upright members 66 and 68.

End support member 70 is attached at its ends to upright members 56 and58, immediate the ends of upright members 56 and 58, and is orientedapproximately parallel to lateral base member 44.

Head bank support beam 76 is attached to the upper ends of uprightmembers 66 and 68 and extends from upright member 68, inward pastupright member 66.

Diagonal support beam 78 is connected on its ends to upright member 54,intermediate the ends of upright member 54, and the outer end of lateralbeam 106. Diagonal support beam 80 is connected on its ends to 1) thelower end of upright member 54 and one end of lateral base member 42 and2) the upper end of upright member 56. Diagonal support beam 82 isattached on its ends to upright member 61, intermediate the ends ofupright member 61, and the outer end of lateral beam 108. Diagonalsupport beam 84 is attached at its ends to 1) the lower end of uprightmember 61 and one end of lateral base member 51 and 2) the upper end ofupright member 60. Diagonal support beam 86 is connected on its ends tothe outer end of lateral base member 48 and the upper end of uprightmember 58. Diagonal support beam 88 is connected on its ends to the endof lateral base member 52 adjacent the lower end of upright member 68and upright member 66.

Longitudinal beam 90 of fixed bank support assembly 72 is attached atone end to the top of upright member 58 and at the other end to uprightmember 66, intermediate the ends of upright member 66. Lateral beam 91is attached on one end to the top of upright member 64 and the other endis attached to longitudinal beam 90. Beam caps 92 and 94 are attached ontop of longitudinal beam 90 as shown in FIG. 2. Beam extension 95 isattached on one end to upright member 66 and extends forward therefrom.Support plates 96 and 98 are fixed on top of beam caps 92 and 94,respectively, and are oriented substantially horizontal. L-shapedmembers 100 and 102 extend between and are connected on their ends tolongitudinal beam 90 and upright members 58 and 62 and form closedframes with those members.

Lateral beam 106 of movable bank support assembly 74 is connected to theupper ends of diagonal support beam 78 and upright members 54 and 56.Lateral beam 108 is connected to the upper ends of diagonal support beam82 and upright members 61 and 60. Longitudinal beam 104 is connected atits ends to lateral beams 106 and 108, near the inner ends of thosebeams. Longitudinal beam 105 is connected at its ends to lateral beams106 and 108. Lateral beam 107 is connected at its ends to longitudinalbeams 104 and 105, substantially at the middle of longitudinal beam 104and 105. Beam extension 110 is attached one end to lateral beam 108 andextends forward thereof.

L-shaped members 101 and 103 extend between and are connected on theirends to longitudinal member 104 and upright members 56 and 60 and formclosed frames with those members.

Rod supports 114, 116 and 118 are affixed to the top of lateral beam106. Rod supports 115, 117 and 119 are affixed to the top of lateralbeam 108. Rod 112 is attached on top of rod supports 114, 116 and 118,substantially parallel to lateral beam 106. Rod 113 is attached on topof rod supports 115, 117 and 119, substantially parallel to lateral beam108.

Bumper assembly 109 includes base plate 354, end plates 356 and 358,housing 360, plunger 362 and spring 364 (see FIG. 3). Base plate 354 isa flat plate attached to the top of lateral beam 107 near the outer endof lateral beam 107. Base plate 354 is oriented substantially horizontaland extends from lateral beam 107 off to one side of lateral beam 107.End plates 356 and 358 are attached to the rearward and forward edges ofbase plate 354 and extend upward therefrom, in parallel. Housing 360 isa hollow cylinder and extends between end plates 356 and 358. Plunger362 is slidably received in and supported by housing 360 and extendsforwardly therefrom. Spring 364 is a helicoidal spring wrapped aroundthe forward end of plunger 362.

Bumper assembly 109 is designed to stop movable bank of stapling units26 and absorb some of the force involved in stopping movable bank 26when movable bank 26 moves from an inner position to its outermostposition, as discussed below. Bank 26 will contact plunger 362, thuscompressing spring 364.

Spacer bar 111 is attached to the top of lateral beam 107 at the forwardend thereof and extends longitudinally along lateral beam 107 asillustrated in FIG. 3. Spacer bar 111 has a plurality of spaced teeth121 extending upward therefrom. Plunger 430 of air cylinder lockassembly 225 is received between adjacent teeth 121 to lock movable bankof stapling units 26 in a fixed position relative support frame assembly22, as discussed below (see also FIG. 16).

FIXED BANK OF STAPLING UNITS

Fixed bank of stapling units 24 includes end support blocks 120 and 122,pivot bar bearing assemblies 124 and 126, pivot bar 128, air cylinderassembly 129, a plurality of stapling unit assemblies 130, a pluralityof clamping assemblies 132, a plurality of combined stapling andclamping assemblies 149, jamb locator 134, air cylinder support plate136, upper air cylinder assembly 138, lower air cylinder assembly 140,trim guide pole 141 and air cylinder assemblies 177 and 179 (see FIGS.1, 4-13 and 35).

End support blocks 120 and 122 are affixed to the top of support plates96 and 98, respectively, of support frame assembly 22 (see FIGS. 4 and12). Pivot bar bearing assemblies 124 and 126 are affixed to the top ofend support blocks 120 and 122, respectively. Pivot bar 128 extendsbetween and has its ends rotatably received in pivot bar bearingassemblies 124 and 126.

Pivot bar 128 has an outer square cross section along all of its length,except for cylindrical ends 142 and 144 (see FIGS. 4, 12 and 28). Thesquare cross section provides four surfaces, including surfaces 143 and145 (see FIGS. 5 and 6), which are perpendicularly oriented and joinedon edge. Cylindrical ends 142 and 144 are rotatably received in pivotbar bearing assemblies 124 and 126, respectively. In this embodiment,pivot bar 128 is an integral member.

Air cylinder assembly 129 includes support member 131, support member139, support arms 147, air cylinder 133, extendable and retractableplunger 135 and gusset plate 137 (see FIGS. 1 and 4). Support member 131is a small beam which extends between and is attached to the undersideof head bank support beam 76 and to the top of lateral beam 91 and isoriented perpendicularly to support beam 76 and lateral beam 91. Supportmember 139 is attached to and supported by support plate 98. Supportarms 147 are a pair of spaced, parallel plates which extend between andare supported on their ends by support member 131 and support member139. The end of air cylinder 133 opposite plunger 135 is rotatablyattached to the outer end of support arms 147. Plunger 135 extends fromone end of air cylinder 133 and is driven by air cylinder 133.

Gusset plate 137 is fixedly attached to surface 145 of pivot arm 128 andextends outwardly therefrom. The free end of plunger 135 is rotatablyattached to gusset plate 137. The extension and retraction of plunger135 causes gusset plate 137, and thus pivot bar 128 and fixed bank 24,to rotate about the axis of pivot bar 128 (see FIG. 4). Fixed bank 24 isin an up position when plunger 135 is retracted and in a down positionwhen plunger 135 is extended.

Stapling unit assemblies 130, clamping assemblies 132 and combinedstapling and clamping assemblies 149 are spaced along pivot bar 128, asillustrated in FIG. 1.

Stapling unit assemblies 130 each include angle plate 146, end brackets148, magazine 150, Z-bar 151, stapler 152, air cylinder assembly 153,pins 367 and pin and bracket assembly 369 (see FIGS. 5-8). Angle plate146 is an elongated angle which is affixed to pivot bar 128. Angle plate146 has flanges 123 and 125. Flange 123 overlaps surface 143 and flange125 overlaps surface 145 of pivot bar 128 (see FIG. 6). End brackets 148extend upwards along the side edges of flange 125.

In this embodiment, Z-bar 151 includes base arm 366, middle arm 368 andtop arm 370 (see FIGS 7 and 8). Base arm 366 and top arm 370 are spaced,substantially in parallel. Middle arm 368 extends diagonally betweenbase arm 366 and top arm 370. Base arm 366 has bores 372 in each end.Middle arm 368 has slots 374 therein. Top arm 370 has bore 376 therein.

Base arm 366 of Z-bar 151 extends between and is rotatably connected toend brackets 146, pins 367 being received through end brackets 146 andin bores 376 of base arm 366. Stapler 152 is fixedly attached to middlearm 368 by pin and bracket assembly 369. The pins of pin and bracketassembly 369 are received through slots 374 in middle arm 368.

Stapler 152 includes an anvil head 154 from which the staples areejected. Stapler 152 is a model sold by BEA. Such staplers are wellknown in this art, and thus stapler 152 is not illustrated or describedin detail herein.

Magazine 150 extends from anvil head 154 rearward of the assembly, underZ-bar 151 and between end brackets 148. Magazine 150 houses a pluralityof staples which are automatically fed to stapler 152.

Air cylinder assembly 153 includes air cylinder 155, bracket 161, endwalls 169 and 171, and retractable and extendable plunger 157. End walls169 and 171 are affixed in parallel. Air cylinder 155 is receivedbetween end walls 169 and 171 and attached thereto. Plunger 157 extendsoutward from and is driven by air cylinder 155. Plunger 157 extendsthrough end wall 171.

Bracket 161 is attached to flange 123 of angle plate 146. End wall 169is rotatably attached to bracket 161. The free end of plunger 157 isrotatably attached to top arm 370 of Z-bar 151 by a pin received in bore376.

Thus, as air cylinder 155 operates, it retracts and extends plunger 157.This, in turn, rotates Z-bar 151 and the entire stapling unit 130 aboutarm 366 of Z-bar 151 between an up position illustrated in FIG. 5 (whenplunger 157 is retracted) and a down position illustrated in FIG. 6(when plunger 157 is extended).

Clamping assemblies 132 each include angle bracket 156, L-shaped supportbracket 158, channel bracket 160, protective material 162, air cylinderassembly 164, plate 378, upper air cylinder assembly 380 and lower aircylinder assembly 382 (see FIGS. 9-11).

Angle bracket 156 is affixed to pivot bar 128 and includes flanges 384and 386 and brackets 388 and 390. Flange 384 overlaps surface 145 andflange 386 overlaps surface 143 of pivot bar 128. Bracket 388 isattached to flange 384 and extends outwardly therefrom. Bracket 390 isattached to flange 386 and extends outwardly therefrom.

Channel bracket 160 includes web 392, bottom flange 394, top flange 396and bracket 398. Bracket 398 is attached to web 392 and is alsorotatably attached to bracket 390 of angle bracket 156. Protectivematerial 162 is placed in channel bracket 160 as a protective layeralong the interior surfaces of web 392 and bottom flange 394. The sizeof the protective material 162 may vary depending on the size of thecasing being attached to the door frame assembly. Protective material162 is readily removable from channel bracket 160 so that differentsizes may be inserted.

L-shaped bracket 158 includes base 163, upright plate 165 and bracket167. Upright plate 165 is attached to the upper surface of top flange396 of channel bracket 160, on edge, and extends upward therefrom. Base163 is attached to the angled lower edge of upright plate 165,substantially perpendicular to upright plate 165, as illustrated in FIG.9. Bracket 167 is attached to upright plate 165 and extends on each sideof upright plate 165, above channel bracket 160.

Air cylinder assembly 164 includes air cylinder 166, extendable andretractable plunger 168 and end walls 173 and 175. End walls 173 and 175are affixed in parallel. Air cylinder 166 extends between and isattached to end walls 173 and 175. End wall 173 is rotatably attached tobracket 388. Plunger 168 extends out one end of air cylinder 166,through end wall 175, and is driven by air cylinder 166. The free end ofplunger 168 is rotatably attached to bracket 167 of L-shaped bracket158.

Thus, the operation of air cylinder 166 causes plunger 168 to extend andretract, rotating L-shaped support bracket 158, channel bracket 160,upper air cylinder assembly 380 and lower air cylinder assembly 382about bracket 390 between an up position (when plunger 168 is retracted,see FIG. 12) and a down position (when plunger 168 is extended, see FIG.9).

Upper air cylinder assembly 380 includes end walls 400 and 402, aircylinder 404 and plunger 406. End walls 400 and 402 are attached to theunderside of base plate 163 of L-shaped support bracket 158, on edge andin parallel. Air cylinder 404 extends between and is supported by endwalls 400 and 402. Plunger 406 extends out of air cylinder 404, throughend wall 400. Plunger 406 is extended and retracted by air cylinder 404.

Plate 378 is attached to end walls 400 and 402 of air cylinder assembly380 and extends vertically therefrom.

Lower air cylinder assembly 382 includes end walls 408 and 410, aircylinder 412 and plunger 414. End walls 408 and 410 are attached toplate 378, on edge and in parallel. Air cylinder 412 is received betweenand supported by end walls 408 and 410. Plunger 414 extends out of aircylinder 412, through end wall 408. Plunger 414 is extended andretracted by air cylinder 412.

Plungers 406 and 414 have retracted positions wherein the free ends ofthe plungers do not contact the casing inserted in channel brackets 160and extended positions wherein the plungers press the casing inserted inchannel brackets 160 against the appropriate jambs, as discussed below(see also FIG. 9).

Combined stapling and clamping assemblies 149 essentially include astapling unit 130 and a clamping assembly 132 attached to a common baseplate, base plate 416 (see FIG. 12).

Base plate 416 is attached to pivot bar 128 and is an angle whichincludes flanges 418 and 420. Flanges 418 and 420 overlap surfaces 143and 145 of pivot bar 128, respectively. The remaining elements ofcombined stapling and clamping assemblies 149 are the same as staplingunits 130 and clamping assemblies 132. Bracket 161 of stapling unit 130and bracket 390 of clamping assembly 132 are integral with flange 416.End brackets 148 of stapling unit 130 and bracket 388 of clampingassembly 132 are integral with flange 418.

Jamb locator 134 is fixedly attached to support plates 96 and 98 (seeFIGS. 1, 6 and 12). Jamb locator 134 has a generally square crosssection with a smooth interior face. Plates can be attached on top ofjamb locator 134 to vary the "height" of jamb locator 134. The desired"height" of jamb locator 134 depends on the dimensions of the jambs ofthe door frame assembly to which casing is to be attached by casingattachment machine 20.

Air cylinder support plate 136 is attached to the end of jamb locator134 opposite head bank of stapling units 28, and is orientedperpendicular to the longitudinal axis of jamb locator 134 (see FIGS. 1and 13). Support plate 136 has holes therein to receive plungers 180, asdiscussed below.

Upper air cylinder assembly 138 and lower air cylinder assembly 140comprise the same elements. Each air cylinder assembly 138 and 140includes base plate 172, end plate 174, a plurality of spaced, parallellongitudinal rods 176, air cylinder 178 and retractable and extendableplunger 180 (see FIG. 13).

Base plate 172 is fixedly attached to air cylinder support plate 136 onthe exterior side of plate 136. Longitudinal rods 176 are attached onone end to base plate 172. End plate 174 is attached to the other endsof longitudinal rods 176, such that rods 176 space base plate 172 andend plate 174 in parallel.

Air cylinder 178 is positioned between and supported by base plate 172and end plate 174, within the "cage" formed by longitudinal rods 176.Plunger 180 extends out one end of air cylinder 178, through holes inbase plate 172 and support plate 136, and is driven by air cylinder 178.

The free end of plunger 180 of upper air cylinder assembly 138 isdesigned to engage the casing and the free end of plunger 180 of lowerair cylinder assembly 140 is designed to engage the jamb when a doorframe assembly and casing are properly received in casing attachmentmachine 20 and the plungers are in their respective extended positions,as discussed below.

Trim guide pole 141 is a straight hollow, square pole attached on oneside of jamb locator 134, near air cylinder assemblies 138 and 140 (seeFIGS. 1 and 13). Trim guide pole 141 is oriented vertically andpositioned such that an end of casing received in casing assemblies 132and combined stapling and casing assemblies 149 will abut trim guidepole 141 when the casing assemblies 132 and combined stapling and casingassemblies 149 are in their up position, as discussed below.

Air cylinder assemblies 177 and 179 each include air cylinder 536,plunger 538, stop 540 and end walls 542 and 544 (see FIG. 35). End wall542 is attached to jamb locator 134, substantially perpendicular to thelongitudinal axis of jamb locator 134. End wall 544 is affixed to endwall 542 in a parallel relationship. Air cylinder 536 is positionedbetween and supported by end walls 542 and 544. Plunger 538 is driven byair cylinder 536 and extends outward therefrom through end wall 542.Stop 540 is attached to the free end of plunger 538 and is received in ahole in the interior surface of jamb locator 134. When plunger 538 is inits retracted position, the outer surface of stop 540 is flush with theinterior surface of jamb locator 134. When plunger 538 is extended, stop540 moves inwardly from jamb locator 134.

MOVABLE BANK OF STAPLING UNITS

Movable bank of stapling units 26 includes slidable frame assembly 182,air cylinder assemblies 183 and 185, end support blocks 184 and 186,pivot bar 188, air cylinder assembly 181, pivot bar bearing assemblies190 and 192, jamb locator 194, a plurality of stapling unit assemblies196, a plurality of clamping assemblies 198, a plurality of combinedstapling and clamping assemblies 213, air cylinder support plate 200,upper air cylinder assembly 202, lower air cylinder assembly 204 andtrim guide pole 215 (see FIGS. 1 and 14-16).

Slidable frame assembly 182 includes main lateral members 206 and 208,top lateral member 210, middle lateral member 212, longitudinal members214 and 216, short longitudinal members 218 and 220, diagonal supportmembers 222 and 224, angle sections 226 and 228, pillow blocks 217, 219,221 and 223 and air cylinder lock assembly 225 (see FIG. 14).

Longitudinal members 214 and 216 extend between and are attached ontheir ends to main lateral members 206 and 208. Main lateral members 206and 208 are spaced in parallel by longitudinal members 214 and 216.Middle lateral member 212 extends between and is attached on its ends tothe approximate centers of longitudinal members 214 and 216. Diagonalsupport members 222 and 224 extend from the internal corners formed bylongitudinal member 214 and middle lateral member 212 to the cornersformed by longitudinal member 216 and main lateral members 206 and 208,respectively. Short longitudinal members 218 and 220 extend between andare attached on their ends to main lateral member 208 and top lateralmember 210. Short longitudinal members 218 and 220 are positioned suchthat they are aligned with longitudinal members 214 and 216,respectively. Top lateral member 210 is attached to the ends of shortlongitudinal members 218 and 220 and is oriented parallel to lateralmembers 206 and 208. Angle sections 226 and 228 are attached to theinterior ends of main lateral members 206 and 208, respectively, suchthat one flange abuts the ends of members 206 and 208 and the otherflange is oriented horizontally.

Air cylinder assembly 183 includes end plate 187, air cylinder 189,extendable and retractable plunger 191 and angle section 193 (see FIG.1).

Extendable and retractable plunger 191 extends out from and is driven byair cylinder 189. End plate 187 is attached on one edge to lateral beam106 of support frame assembly 22 and extends substantially perpendicularthereto. The end of air cylinder 189 opposite plunger 191 is attached toend plate 187. Air cylinder 189 is oriented substantially parallel tolateral beam 106. One flange of angle section 193 is attached to mainlateral member 206 of slidable frame assembly 182. The free end ofplunger 191 is attached to the other flange of angle section 193.

Air cylinder assembly 185 includes end plate 195, air cylinder 197,extendable and retractable plunger 199 and end plate 201 (see FIG. 1).

Plunger 199 extends out of and is driven by air cylinder 197. End plate195 is attached on one edge to lateral beam 108 of support frameassembly 22 and extends substantially perpendicular thereto. The end ofair cylinder 197 opposite plunger 199 is attached to end plate 195 andis oriented substantially parallel to lateral beam 108. End plate 201 isattached to short longitudinal member 220 of slidable frame assembly182. The free end of plunger 199 is attached to end plate 201.

Air cylinder assemblies 183 and 185 slide slidable frame assembly 182relative support frame assembly 22, as discussed in detail below, sincethe ends of air cylinders 189 and 197 opposite plungers 191 and 199 areattached to frame assembly 22 and plungers 191 and 199 are attached toslidable frame assembly 182. When plungers 191 and 199 are retracted,frame assembly 182, and thus movable bank 26, is in the retractedposition. When plungers 191 and 199, are extended, frame assembly 182,and thus movable bank 26, is in its innermost position.

End support blocks 184 and 186 are affixed to the interior surfaces ofangle sections 226 and 228, respectively (see FIGS. 19 and 32). Pivotbar bearing assemblies 190 and 192 are attached to the top of endsupport blocks 184 and 186, respectively.

Pivot bar 188 extends between and is rotatably received within pivot barbearing assemblies 190 and 192. Pivot bar 188 has a square outer crosssection along all of its length, except for cylindrical ends 237 and239. Cylindrical ends 237 and 239 are rotatably received within pivotbar bearing assemblies 190 and 192, respectively.

Pillow blocks 217 and 219 are attached to the under side of main lateralmember 206 and slidably receive rod 112 therein. Pillow blocks 221 and223 are attached to the underside of main lateral member 208 andslidably receive rod 113 therein.

Air cylinder lock assembly 225 includes base plate 422, end walls 424and 426, air cylinder 428 and extendable and retractable plunger 430(see FIG. 16). Base plate 422 is attached to middle lateral member 212and extends vertically downward therefrom. End walls 424 and 426 areattached on edge to base plate 422 and extend horizontally therefrom, inparallel. Air cylinder 428 is received between and supported by endwalls 424 and 426. Plunger 430 extends downward from air cylinder 428,through end wall 426 and is retracted and extended by air cylinder 428.The free end of plunger 430 is designed to be received between andengage adjacent teeth 121 of spacer bar 111 when plunger 430 is in thedown position.

When plunger 430 engages teeth 121, movable bank 26 is held in a fixedposition relative support frame assembly 22. When plunger 430 isretracted, plunger 430 disengages teeth 121 and movable bank 26 is freeto move relative support frame assembly 22 (see FIG. 3).

Air cylinder assembly 181 includes support member 203, air cylinder 205,extendable and retractable plunger 207, gusset plate 209 and bracket 211(see FIG. 15).

Support member 203 is attached to main lateral member 208 of slidableframe assembly 182 and extends parallel to main lateral member 208.Plunger 207 extends from and is driven by air cylinder 205. The end ofair cylinder 205 opposite plunger 207 is rotatably attached to supportmember 203 by bracket 211. Gusset plate 209 is affixed to pivot bar 188.The free end of plunger 207 is rotatably attached to gusset plate 209.The extension and retraction of plunger 207 by air cylinder 205 causesgusset plate 209, and thus pivot bar 188, to rotate around the axis ofrotation of pivot bar 188. When plunger 207 is in its retractedposition, movable bank 26 is rotated to its up position. When plunger207 is extended, movable bank 26 is rotated to its down position.

Jamb locator 194 is fixedly attached to and extends between anglesections 226 and 228 (see FIG. 1). Jamb locator 194 has a flat interiorsurface.

Stapling unit assemblies 196, clamping assemblies 198, combined staplingand clamping assemblies 213, air cylinder support plate 200, upper aircylinder assembly 202, lower air cylinder assembly 204 and trim guidepole 215 are the same as stapling unit assemblies 130, clampingassemblies 132, combined stapling and clamping assemblies 149, aircylinder support plate 136, upper air cylinder assembly 138, lower aircylinder assembly 140, and trim guide pole 141, respectively, and thusare not illustrated or described in detail herein.

HEAD BANK OF STAPLING UNITS

Head bank of stapling units 28 includes pivot bar bearing assemblies 232and 234, pivot bar 236, secondary pivot bar assemblies 229 and 230,stationary stapling unit assemblies 233 and 235, movable stapling unitassembly 238, linear stapling unit drive assembly 240, clampingassemblies 242 and 244, ejection air cylinder assemblies 243 and 245,trim guide assembly 247 and air cylinder assembly 249 (see FIGS. 1,17-24 and 34).

Pivot bar bearing assembly 232 is attached to the top of beam extension95 (see FIG. 24) and pivot bar bearing assembly 234 is attached to thetop of beam extension 110 of support frame assembly 22 (see FIG. 1).

Pivot bar 236 extends between and is connected on its ends to pivot barbearing assemblies 232 and 234. Pivot bar 236 has a square outer crosssection along its entire length, except for its end portions which arecylindrical. The cylindrical end portions are rotatably received withinpivot bar bearing assemblies 232 and 234. Pivot bar 236 is rotated byair cylinder assembly 249, as discussed below.

Secondary pivot bar assemblies 229 and 230 each include plate 268,support blocks 270, pivot bar bearing assemblies 272 and 274 andsecondary pivot bar 276 (see FIGS. 17-21).

Plate 268 of secondary pivot bar assembly 229 is attached to the bottomof head bank support beam 76 of support frame assembly 22 and extendsinwardly therefrom. Plate 268 of secondary pivot bar assembly 230 isattached to the bottom of lateral member 210 of slidable frame assembly182 and extends inwardly therefrom. Plates 268 are orientedsubstantially horizontal.

Support blocks 270 are attached to the top of plates 268, with a pair ofsupport blocks 270 on each plate 268. Each pair is spaced apart. A pivotbar bearing assembly 272 is attached to the top of one support block 270of each pair and a pivot bar bearing assembly 274 is attached to the topof the other support block 270 of each pair. Secondary pivot bar 276extends between and is rotatably received in pivot bar bearingassemblies 272 and 274.

Clamping assembly 242 includes gusset plate 306, arms 308, bracket 310,channel bracket 312, L-shaped bracket 314, air cylinder assembly 316,protective material 318 and air cylinder assembly 319 (see FIGS. 17, 18and 23).

Gusset plate 306 is fixedly attached to and extends outwardly from pivotbar 236. Arms 308 are elongated, spaced plates which are rotatablyattached to gusset plate 306 at one end and to bracket 310 at the otherend.

Bracket 310 is generally of a "U" shape. Bracket 310 is fixedly attachedto secondary pivot bar 276 near the bottom of the "U". Arms 308 arerotatably attached to one arm of the "U" and one corner of channelbracket 312 is rotatably attached to the other arm of the "U" formed bybracket 310. Protective material 318 is provided in the interior ofchannel bracket 312 and is readily removable so that different sizes ofprotective material can be inserted in channel bracket 312, as desired.

L-shaped bracket 314 has arms 320 and 322. Arm 320 is attached to thetop flange of channel bracket 312. Air cylinder assembly 316 is attachedto arm 322, as discussed below.

Air cylinder assembly 316 includes end walls 315 and 317, air cylinder324, plunger 326 and plate 329. Plate 329 is attached to the edge of arm322 of L-shaped bracket 314, perpendicular to arm 322. End walls 315 and317 are affixed to plate 329, on edge and in parallel. Air cylinder 324is positioned between and supported by end walls 315 and 317. Plunger326 extends out from and is driven by air cylinder 324. Plunger 326extends through end wall 315 and, when extended, is designed to holdcasing in abutment with a door frame assembly, as discussed below.

Air cylinder assembly 319 includes air cylinder 321, plunger 327 and endwalls 337 and 339. End walls 337 and 339 are fixed in parallel. Aircylinder 321 is positioned between and supported by end walls 337 and339. Plunger 327 is driven by air cylinder 321 and extends from aircylinder 321 through end wall 339. End wall 337 is rotatably attached tobracket 310, proximate the connection of arms 308 to bracket 310, by pin333. The free end of plunger 327 is rotatably attached to arm 320 ofL-shaped bracket 314.

The extension and retraction of plunger 327 causes channel bracket 312,L-shaped bracket 314 and air cylinder assembly 316 to rotate around theaxis of rotation of channel bracket 312 (see FIG. 21). When plunger 327is retracted, channel bracket 312, L-shaped bracket 314 and air cylinderassembly 316 are in their up position. When plunger 327 is extended,channel bracket 312, L-shaped bracket 314 and air cylinder 316 arerotated to their down position.

Clamping assembly 244 includes bracket 310, channel bracket 312,L-shaped bracket 314, air cylinder assembly 316, protective material 318and air cylinder assembly 319 (see FIGS. 19 and 21), the same asclamping assembly 242, but does not include gusset plate 306 and arms308. Gusset plate 306 and arms 308 are essentially replaced by collar432, air cylinder assembly 434, sliding blocks 436, arms 438 and arms440.

Collar 432 encompasses pivot bar 236. Sliding blocks 436 are positionedand retained between collar 432 and pivot bar 236.

Air cylinder assembly 434 is attached to the exterior of collar 432 andincludes air cylinder 442 and plunger 444. Plunger 444 is driven by aircylinder 442 and extends out of air cylinder 442, through collar 432.The free end of plunger 444 is in abutment with sliding blocks 436. Whenplunger 444 is extended, it pushes sliding blocks 436 firmly againstpivot bar 236 such that sliding blocks 436 and the entire clampingassembly 244 cannot slide relative pivot bar 236. When plunger 444 isretracted, clamping assembly 244 can slide relative pivot bar 236.

Arms 438 are elongated, spaced plates which extend between and areconnected at their ends to top lateral member 210 of slidable frameassembly 182 and collar 432, such that collar 432, and thus clampingassembly 244, moves with slidable frame assembly 182. Arms 440 areelongated, spaced plates which extend between and are rotatablyconnected on their ends to collar 432 and bracket 310.

Stationary stapling unit assemblies 233 and 235 each include stapler446, magazine 448, bracket 450, air cylinder assembly 452 and gussetplate 463 (see FIGS. 20 and 22). Stapler 446 is rotatably attached toarms 308. Magazine 448 extends from the anvil of stapler 446 backwardunder stapler 446. Magazine 448 supplies staples to stapler 446.Staplers and magazines, such as stapler 446 and magazine 448 are wellknown in this industry, and thus stapler 446 and magazine 448 are notdescribed in detail herein.

Bracket 450 is attached to the underside of magazine 448 and extendsdownwardly therefrom. Gusset plate 463 is attached to secondary pivotbar 276 and extends outwardly therefrom, parallel to the outer wall ofbracket 310.

Air cylinder assembly 452 includes pivot pin 454, end walls 456 and 458,air cylinder 460 and plunger 462. Pivot pin 454 extends between one sidewall of bracket 310 and gusset plate 463. End wall 456 is rotatablyattached to pivot pin 454. End walls 456 and 458 are affixed inparallel. Air cylinder 460 is received between and supported by endwalls 456 and 458. Plunger 462 is driven by air cylinder 460 and extendsoutwardly therefrom, through end wall 458. The free end of plunger 462is rotatably attached to bracket 450. The extension and retraction ofplunger 462 causes stapler 446 to rotate about the connection of stapler446 to arms 308 (see FIG. 22). When plunger 462 is retracted, stapler446 is in its down position. When plunger 462 is extended, stapler 446is rotated to its up position.

Movable stapling unit assembly 238 includes collar assembly 278, slideblocks 290, arm 280, secondary arm 282, stapler 284, bracket 286,magazine 288, air cylinder assembly 289 and air cylinder assembly 291(see FIGS. 18 and 34).

Collar assembly 278 encompasses pivot bar 236. Slide blocks 290 arepositioned and retained between collar assembly 278 and pivot bar 236.

Arm 280 is an elongated arm which is attached on one end to collarassembly 278 and extends outward therefrom. Stapler 284 is rotatablyattached to the other end of arm 280. Stapler 284 includes anvil 285.Magazine 288 extends between anvil 285 and the connection of stapler 284to arm 280 and automatically supplies staples to stapler 284. Staplersand magazines, such as stapler 284 and magazine 288, are well known inthis industry and thus are not described in detail herein.

Bracket 286 is attached to the underside of magazine 288. Secondary arm282 is fixedly attached to arm 280 on one end, about halfway between theends of arm 280, and extends inward therefrom.

Air cylinder assembly 289 includes end walls 292 and 294, air cylinder296 and plunger 298. End walls 292 and 294 are affixed in parallel. Aircylinder 296 is positioned between and supported by end walls 292 and294. Plunger 298 is driven by air cylinder 296 and extends therefrom,through end wall 294. End wall 292 is rotatably attached to the outerend of secondary arm 282. The free end of plunger 298 is rotatablyattached to bracket 286. The extension and retraction of plunger 298causes stapler 284 to rotate about the axis of rotation between stapler284 and arm 280. When plunger 298 is retracted, stapler 284 is in itsdown position. When plunger 298 is extended, stapler 284 is in its upposition.

Air cylinder assembly 291 includes end plates 293 and 295, air cylinder297 and a plunger (not shown). End plate 293 is attached to collarassembly 278. End plate 295 is fixedly spaced from end plate 293, inparallel. Air cylinder 297 is positioned between and supported by endplates 293 and 295. The plunger is driven by and extends out of aircylinder 297 through end plate 293. The free end of the plunger is inabutment with sliding block 298. When the plunger is fully extended, theplunger presses sliding block 298 into firm engagement with pivot bar236, preventing the movement of movable stapling unit assembly 238 alongpivot bar 236. When the plunger is retracted, sliding block 298, andthus the entire movable stapling unit assembly 238, is free to movealong pivot bar 236.

Linear staple unit drive assembly 240 includes linear motor 246 andretractable and extendable plunger 248 (see FIG. 34). Linear motor 246is attached to one end of pivot bar 236. Plunger 248 is driven by linearmotor 246 and extends out therefrom, parallel to pivot bar 236. The freeend of plunger 248 is affixed to collar assembly 278 of movable staplingunit assembly 238.

Linear motor drive 246 is employed to move stapling unit assembly 238along pivot bar 236. Linear motor drive 246 and stapling unit assembly238 are controlled by programmable controller 38 (discussed below) suchthat, once it is ready to proceed with attachment of a piece of headcasing to the head jamb of a structural frame assembly, stapling unitassembly 238 is driven along pivot bar 236 by linear motor drive 246,stopped at selected intervals and injects staples at selected intervals,as discussed below.

Ejection air cylinder assemblies 243 and 245 each include base plate331, air cylinder assembly 323 and plunger 325 (see FIGS. 17-20). Baseplate 331 is attached to plate 268 and is oriented horizontally.

Air cylinder assembly 323 includes end walls 300 and 301, air cylinder302 and plunger 325. End walls 300 and 301 are attached, on edge and inparallel, to base plate 331. Air cylinder 302 is positioned between andsupported by end walls 300 and 301. Plunger 325 is driven by aircylinder 323 and extends outwardly therefrom, through end wall 301.Plungers 325, when retracted, are designed to engage door frame assembly21 when door frame assembly 21 is positioned in casing attachmentmachine 20, and function as a reference point for the head of door frameassembly 21. When plungers 325 are extended, they push door frameassembly 21 away from head bank of stapling units 28, as describedbelow.

Trim guide assembly 247 includes base plate 464, pole 466 and aircylinder assembly 468 (see FIGS. 17 and 34). Base plate 464 is attachedto the top of head bank support beam 76. Pole 466 is attached to baseplate 464, on end, and extends upwardly therefrom. Air cylinder assembly468 is attached to the top end of pole 466.

Air cylinder assembly 468 includes end walls 470 and 472, air cylinder474 and plunger 476. End wall 470 is attached to the top of pole 466.End wall 472 is fixedly attached to end wall 470, in parallel. Aircylinder 474 is positioned between and supported by end walls 470 and472. Plunger 476 is driven by air cylinder 474 and extends outwardlytherefrom, through end wall 470 and pole 466.

When plunger 476 is extended, its free end is in line with head casing23 placed in channel brackets 312 of clamping assemblies 242 and 244when clamping assemblies 242 and 244 are in the up position. Thus,plunger 476 functions as a guide for head casing 23 when head casing 23is placed in clamping assemblies 242 and 244.

Air cylinder assembly 249 includes base plate 478, air cylinder 480,plunger 482 and gusset plate 484 (see FIG. 24). Plunger 482 extends outone end of air cylinder 480 and is driven by air cylinder 480.

Base plate 478 is attached to support frame assembly 22. The end of aircylinder 480 opposite plunger 482 is rotatably attached to base plate478. Gusset plate 484 is attached to pivot bar 236. The free end ofplunger 482 is rotatably attached to gusset plate 484. The extension andretraction of plunger 482 causes pivot bar 236, and thus head bank 28,to rotate about the axis of rotation of pivot bar 236. When plunger 482is retracted, head bank 28 is in its up position. When plunger 482 isextended, head bank 28 is rotated to its down position.

CORNER SPLICING ASSEMBLIES

Corner splicing assembly 30 is attached to and supported by top lateralmember 210 of slidable frame assembly 182. Corner splicing assembly 32is attached to and supported by head bank support beam 76.

Corner splicing assemblies 30 and 32 each include base support plates231 and 250, head assembly 251, side guide bars 259, linkage 262,upright air cylinder assembly 264, upright support plates 266, top crossplate 257 and clamping assembly 267 (see FIGS. 25-30).

Base support plate 231 of corner splicing assembly 30 is attached to thetop of top lateral member 210 and base support plate 231 of cornersplicing assembly 32 is attached to the top of head bank support beam76. Base support plate 250 is attached to the top of base support plate231. Base support plates 231 and 250 are oriented horizontally.

Side guide bars 259 are angles attached to base support plate 250 in aspaced, parallel relationship. Side guide bars 259 have one flange ofthe angle attached to base support plate 250, on edge. The other flangeis parallel to base plate 250, spaced above base plate 250. The"interior" of the angles face one another.

Head assembly 251 includes base plate 241, casing support plate 252,base 253, spline guides 254 and 256 and air cylinder assembly 260. Headassembly 251 is slidably supported by base support plate 250 and sideguide bars 259 and is slidably driven by air cylinder assembly 264, asdiscussed below.

Base plate 241 is slidably received on base support plate 250 betweenthe lower flanges of side guide bars 259 (see FIG. 29). The upperflanges of side guide bars 259 overlap the longitudinal edges of baseplate 241 to partially retain base plate 241 between guides bars 259.Base 253 and air cylinder assembly 260 are attached to the top of baseplate 241.

Casing support plate 252 is a flat plate which extends horizontally outthe front of base 253 and is designed to receive edges of casing 25 and27, as discussed below. Spline guides 254 and 256 extend upward frombase 253 and have a polygonal cross-sectional shape forming frontsurfaces 263 and 265, respectively, as illustrated in FIG. 26. Frontsurfaces 263 and 265 form the sides of a ninety degree corner. Splineguides 254 and 256 are spaced apart such that a channel is formedbetween them. Casing support plate 252, base 253 and spline guides 254and 256 can be an integral member or can be a series of connectedpieces.

Air cylinder assembly 260 includes end walls 269 and 271, air cylinder273, plunger 261 and driver 258. End walls 269 and 271 are attached tothe top of base plate 241, on edge and in parallel. Air cylinder 273 ispositioned between and supported by end walls 269 and 271. Plunger 261is driven by air cylinder 273 and extends out one end thereof throughend wall 269.

Driver 258 is attached to the free end of plunger 261. Driver 258 is aflat plate slidably received in the channel formed between spline guides254 and 256. Driver 258 is designed to be reciprocated in the channelformed between spline guides 254 and 256 to drive splines into thecorner of the casing retained on casing support plate 252 as discussedbelow. The extension and retraction of plunger 261 slides driver 258between spline guides 254 and 256 (see FIGS. 27A and 27B).

Upright support plates 266 are attached to base support plate 250 onedge, in parallel. Top cross plate 257 extends between and is attachedto the top of upright support plates 266 to form a closed frame.

Upright air cylinder assembly 264 includes end walls 275 and 277, aircylinder 279 and plunger 281. End walls 275 and 277 extend between andare attached to upright support plates 266, in parallel. Air cylinder279 is positioned between and supported by end walls 275 and 277.Plunger 281 is driven by air cylinder 279 and extends out one end of aircylinder 279, through end wall 275.

Linkage 262 includes links 486 and 488 and base 490 (see FIG. 27). Base490 is attached to one of upright support plates 266. One end of link486 is rotatably attached to base 490 and the other end is rotatablyattached to the free end of plunger 281. One end of link 488 isrotatably attached to the free end of plunger 281 and the other end isrotatably attached to end wall 271 of air cylinder assembly 260. Theextension and retraction of plunger 281 causes the angle formed by links486 and 488 to expand and contract (see FIGS. 27A and 27B). Since link488 is attached to air cylinder assembly 260 which is in turn attachedto base plate 241, extension and retraction of plunger 281 causes headassembly 251 to slide relative base support plate 250. When plunger 281is retracted, head assembly 251 is in its retracted position. Whenplunger 281 is extended, head assembly 251 is in its outward position.

Corner clamping assembly 267 includes air cylinder assembly 328 andclamp assembly 330 (see FIGS. 20, 29 and 30).

Air cylinder assembly 328 includes base bracket 492, air cylinder 494,end walls 496 and 498 and plunger 500. Base bracket 492 includes web 502and flanges 504. Web 502 abuts and is attached to spline guide 256 ofcorner splicing assembly 32. In corner splicing assembly 30, web 502 isattached to spline guide 254. Flanges 504 extend vertically from web502, in parallel. End wall 496 extends between and is attached to thetop ends of flanges 504. End wall 498 is fixedly attached to end wall496, in parallel. Air cylinder 494 is positioned between and supportedby end walls 496 and 498. Plunger 500 is driven by air cylinder 494 andextends out of one end of air cylinder 494, through end wall 496.

Clamp assembly 330 includes links 506, bracket 508, bracket 510, arm512, cross bar 332, threaded shafts 334 and rubber stops 335.

Bracket 508 is fixedly attached to web 502 and extends upward therefrom,between flanges 504. In this embodiment, bracket 508 includes a pair ofparallel, triangular plates, oriented vertically.

Links 506 are rotatably attached, on one end, to bracket 508 at onelower corner thereof. Links 506 are a pair of links, one located on eachside of bracket 508. The other end of links 506 is rotatably attached tothe free end of plunger 500 of air cylinder assembly 328.

Bracket 510 is in the shape of a "U", with arm 512 being received withinthe "U". Bracket 510 is rotatably attached to the free end of plunger500 and also is rotatably attached to arm 512, immediate the ends of arm512.

One end of arm 512 is rotatably attached to bracket 508 near the apex ofbracket 508. Cross bar 332 is fixedly attached to the other end of arm512. Shafts 334 extend through cross bar 332 and threadedly engage crossbar 332 so that the length of shafts 334 on the front side of cross bar332 can be varied. Rubber stops 335 are attached on the front ends ofshafts 334.

The retraction and extension of plunger 500 causes links 506 to rotaterelative bracket 508 and bracket 510 to rotate about the connection ofbracket 510 to plunger 500 (see FIGS. 29 and 30). This action causes arm512 to rotate about its connection with bracket 508. Since cross bar 332is attached to one end of arm 512, cross bar 332 and shafts 334 rotatein an arc having the connection of arm 512 to bracket 508 as the centerof the arc. When plunger 500 is retracted, clamp assembly 330 is in itsup position. When plunger 500 is extended, clamp assembly is rotated toits down position and rubber stops 335 are pressed against casingreceived on casing support plate 252.

LIFTING ASSEMBLY

Lifting assembly 34 includes air cylinder assemblies 336, 338, 340 and342 and cross beam assemblies 344 and 346 (see FIGS. 2, 31 and 32).

Each air cylinder assembly 336, 338, 340 and 342 includes air cylinder350 and extendable and retractable plunger 352. Air cylinder assemblies336, 338, 340 and 342 are attached to the vertical arms of L-shapedmembers 101, 103, 102 and 100, respectively, of bottom support frameassembly 22, such that air cylinders 350 are oriented vertically.Extendable and retractable arms 352 are driven by air cylinders 350 andextend out the top end of air cylinders 350.

Cross beam assembly 344 is supported on its ends by the free ends ofplungers 352 of air cylinder assembly 336 and air cylinder assembly 340.Cross beam assembly 346 is supported at its ends by the free ends ofplungers 352 of air cylinder assembly 338 and air cylinder assembly 342.

The operation of air cylinder assemblies 336, 338, 340 and 342 controlsthe raising and lowering of cross beam assemblies 344 and 346. Whenplungers 352 are retracted, cross beam assemblies 344 and 346 are intheir lowered position. When plungers 352 are extended, cross beamassemblies 344 and 346 are in their raised position.

Cross beam assemblies 344 and 346 each include beam 341, a plurality ofprotractable support squares 345 and air cylinder assemblies 347. Beam341 is an elongated beam. Protractable support squares 345 are spacedserially along the approximate left half of beam 341. Air cylinderassemblies 347 are positioned under the approximate left half of beam341. There is an air cylinder assembly 347 for each protractable supportsquare 345.

The air cylinder assemblies 347 function to raise and lower theprotractable support squares 345 as desired, as discussed below. Whenthe plunger of an air cylinder assembly 347 is retracted, the topsurface of the corresponding support square 345 is flush with the topsurface of beam 341. When a plunger of an air cylinder assembly 347 isextended, the corresponding support square 345 is pushed above the topsurface of beam 341.

CONVEYOR BELT ASSEMBLY

Conveyor belt assembly 36 is a conventional conveyor belt assembly andthus is not illustrated or described in detail herein. Conveyor beltassembly 36 extends longitudinally between cross beam assemblies 344 and346.

PROGRAMMABLE CONTROLLER

Programmable controller 38 is a programmable logic controller (PLC).Since such controllers are well known in this industry and are availablefrom many manufacturers, controller 38 is not described or illustratedin detail herein. Programmable controller 38 is electronically connectedto all of the sub-assemblies of casing support machines 20 and to allelements of the assembly line as discussed below (see FIG. 33).Programmable controller 38 functions to operate and coordinate allelements of casing attachment machine 20 and of the assembly line.

ASSEMBLY LINE

Casing attachment machine 20 can be employed in a variety ofmanufacturing situations, varying from a single machine 20 fed doorframes and casing by hand and removed by hand to a more complexsemi-automatic assembly line as illustrated in FIG. 33.

The assembly line illustrated in FIG. 33 includes, in seriatim, inputstation 516, rollers 518, a first casing attachment machine 20, conveyor520, door frame turning station 522, conveyor 524, a second casingattachment machine 20, conveyor 526 and output station 528. In addition,the assembly line includes glue applying station 530, chutes 532 andoperator's stations 534.

Input station 516 is designed to receive a door frame assembly, withoutcasing. Input station 516 can be as simple as a flat table, oradditional guides may be provided.

Rollers 518 are idle rollers. Rollers 518 and conveyors 520, 524 and 526are conventional in this industry and thus are not illustrated ordescribed in detail herein.

Door frame turning station 522 is a station at which the door frameassembly, now with casing attached on one side, is manually orautomatically turned 180 degrees.

Output station 528 is designed to receive a door frame, with casing onboth sides, off of conveyor 526. Output station 528 can be a simpletable or a more complex work station wherein follow-up functions can beperformed.

Glue applying station 530 is designed to automatically apply glue to theleading edge of casing fed through glue applying station 530. Chutes 532extend between glue applying station 530 and operator's stations 534 totransport the casing, now with glue applied on the leading edge, to theoperator's stations 534.

Each operator's station 534 includes a control panel for controlling thecorresponding casing attachment machine 20, as well as conveyors 520,524 and 526 and door frame turning station 522. The control panel mayalso include indicator and/or warning lights or gauges.

Programmable logic controller 38 is connected to casing attachmentmachines 20, conveyors 520, 524 and 526, door frame turning station 522(if automatic), glue applying station 530 and operator's stations 534 toproperly sequence the operation of all of these elements.

OPERATION

Casing attachment machine 20 is designed to be used as part of anassembly line as illustrated in FIG. 33 and as discussed above.

The assembly line is employed by placing a door frame assembly, withoutcasing, such as door frame assembly 21, on input station 516 (see FIG.33). After door frame assembly 21 is properly positioned on inputstation 516, door frame assembly 21 is pushed over rollers 518 into thefirst casing attachment machine 20. The first casing attachment machine20 operates to attach casing on one side of door frame assembly 21, asdiscussed below.

When door frame assembly 21 is to be received in the first casingattachment machine 20, i.e., when casing attachment machine 20 is in the"start" position (see FIG. 36A), plungers 352 of air cylinder assemblies336, 338, 340 and 342 are in their lowermost or down position (see FIG.36B). When plungers 352 are in this position, the top surfaces of crossbeam assemblies 344 and 346 are just below the top surfaces of rollers518 and of the conveyor of conveyor belt assembly 36. Thus, when thedoor frame assembly is pushed over rollers 518 into the first casingattachment machine 20, the door frame assembly comes to rest on theconveyor belt of conveyor belt assembly 36.

In addition, when casing attachment machine 20 is in the "start"position, plunger 191 of air cylinder assembly 183 and plunger 199 ofair cylinder assembly 185 are in their extended position, positioningmovable bank of stapling units 26 in its innermost position, i.e.,closest to fixed bank of stapling units 24.

Further, plungers 135, 207 and 482 of air cylinder assembly 120 (offixed bank 24), air cylinder assembly 181 (of movable bank 26) and aircylinder assembly 249 (of head bank 28), respectively, are in theirretracted positions (see FIGS. 4, 15, 24 and 36A). This retains pivotbars 128, 188 and 236 of fixed bank of stapling units 24, movable bankof stapling units 26 and head bank of stapling units 28, respectively,such that 1) stapling units 130, clamping assemblies 132 and combinedstapling and clamping units 149 of fixed bank of stapling units 24, 2)stapling units 196, clamping assemblies 198 and combined stapling andclamping units 213 of movable bank of stapling units 26 and 3) staplingunits 233, 235 and 238 and clamping assemblies 242 and 244 of head bankof stapling units 28 are in their raised or up positions.

Likewise, plungers of 157 of air cylinder assemblies 153 of 1) staplingunit assemblies 130 of fixed bank 24, 2) combined stapling and clampingunits 149 of fixed bank 24, 3) stapling unit assembly 196 of movablebank 26, and 4) combined stapling and clamping units 213 of movable bank26 are in their respective extended positions, thus holding all of thestaplers 152 of said units in their uppermost position (see FIGS. 5 and12). Plungers 168 of air cylinder assemblies 164 of 1) clampingassemblies 132 of fixed bank 24, 2) combined stapling and clamping units149 of fixed bank 24, 3) clamping assemblies 198 of movable bank 26 and4) combined stapling and clamping units 213 of movable bank 26 are intheir retracted positions, thus retaining all of the L-shaped brackets158 and channel brackets 160 in their uppermost positions (see FIGS. 9and 12).

In addition, plungers 180 of 1) upper air cylinder assembly 138 andlower air cylinder assembly 140 of fixed bank 24 and 2) upper aircylinder assembly 202 and lower air cylinder assembly 204 of movablebank 26 are in their retracted positions so that plungers 180 will notengage the door frame assembly when door frame assembly 21 is initiallyreceived and positioned within casing attachment machine 20 (see dashedlines in FIG. 13). Plunger 430 of air cylinder lock assembly 225 ofslidable frame assembly 182 is in the retracted position such thatplunger 430 is disengaged from spacer bar 11 and slidable frame assembly182 is free to slide relative bottom support frame assembly 22 (see FIG.3). Plungers 538 of air cylinder assemblies 177 and 179 of fixed bank 24are in their retracted positions such that the interior surfaces ofstops 540 are flush with the interior surface of jamb locator 134 (seeair cylinder assembly 177 as illustrated by FIG. 35).

Moreover, with respect to head bank 28, plungers 327 of air cylinderassemblies 319 of clamping assemblies 242 and 244 are in theirrespective retracted positions, so that the respective L-shaped brackets314 and channel brackets 312 are in their uppermost position (see FIGS.17-21). Plungers 462 of air cylinder assemblies 452 of stationarystapling unit assemblies 233 and 235 are in their extended position toretain staplers 446 in their respective uppermost position. Plunger 298of air cylinder assembly 289 of movable stapling unit assembly 238 is inits extended position, holding stapler 284 in its uppermost position(see FIG. 18). Plungers 325 of ejection air cylinder assemblies 243 and245 are in their respective retracted positions, so that plungers 325 donot interfere when door frame assembly 21 is received in casingattachment machine 20 (see FIGS. 18 and 19). The plunger of air cylinderassembly 291 of movable stapling unit assembly 238 and plunger 444 ofair cylinder assembly 434 of clamping assembly 244 are in theirrespective retracted positions such that movable stapling unit assembly238 and clamping assembly 244 can be slid along pivot bar 236 (see FIGS.18 and 21). Plunger 476 of air cylinder assembly 468 of trim guideassembly 247 is in its extended position, extending through and belowpole 466 (see FIG. 17). With respect to head bank 28, plunger 248 oflinear staple unit drive assembly 240 is in its retracted position suchthat movable stapling unit assembly 238 is in its position closest toclamping assembly 242 (see FIGS. 18 and 36A).

With respect to corner splicing assemblies 30 and 32, plungers 281 ofair cylinder assemblies 264 are in their retracted positions, holdinghead assemblies 251 in their retracted positions (see FIG. 27). Plungers261 of air cylinder assemblies 260 are in their retracted positions,holding drivers 258 in their retracted position (see FIGS. 25-27). Last,with respect to corner splicing assemblies 30 and 32, plungers 500 ofair cylinder assemblies 328 of clamping assemblies 267 are in theirretracted positions, holding clamping assemblies 267 in their uppermostpositions (see FIG. 30).

All of the plungers of air cylinder assemblies 347 are in theirrespective retracted positions such that the top surfaces of supportsquares 345 are flush with the top surface of cross beams 344 and 346(see FIG. 32).

Finally, plungers 326 of air cylinder assemblies 316 of clampingassemblies 242 and 244 of head bank 28, and plungers 406 and 414 of aircylinder assemblies 380 and 382, respectively, of 1) clamping assemblies132 and combined clamping and stapling assemblies 149 of fixed bank 24and 2) clamping assemblies 198 and combined clamping and staplingassemblies 213 of movable bank 26 are in their retracted positions sothat casing can be placed in channel brackets 312 of clamping assemblies242 and 244 of head bank 28 and channel brackets 160 of 1) clampingassemblies 132 and combined stapling and clamping units 149 of fixedbank 24 and 2) clamping assemblies 198 and combined stapling andclamping units 213 of movable bank 26 (see FIGS. 9, 12 and 17-19).

After door frame assembly 21 passes over rollers 518, door frameassembly 21 engages conveyor 36 which is operated to transport doorframe assembly 21 within support frame assembly 22, and centered overcross beam assemblies 344 and 346 (see FIG. 36B).

When door frame assembly 21 is received within support frame assembly 22of casing attaching machine 20, and positioned over cross beamassemblies 344 and 346, the operator of casing attachment machine 20,positioned at operator's station 534, informs programmable logiccontroller 38 of the size door frame assembly which is in casingattachment machine 20 by pushing the appropriate buttons.

Next, the operator places splines 29 in front of drivers 258, in thechannels formed between spline guides 254 and 256 of corner splicingassemblies 30 and 32 (see FIG. 26). Splines 29 lay flat in the channels.

The operator then places right side casing 25 in the channel brackets160 of clamping assemblies 132 and combined stapling and clamping units149 of fixed bank 24 and left side casing 27 in channel brackets 160 ofclamping assemblies 198 and stapling and clamping units 213 of movablebank 26 (see FIG. 36B). Casing 25 and 27 is received from glue applyingstation 530 via a chute 532 with glue applied to the under side of itsleading edge. Casing 25 and 27 is placed flat with its lower surfaceagainst the bottom of protective material 162 and its back edge againstthe side of protective material 162 in the channel brackets 160 (seeFIGS. 9 and 12). Longitudinally, the lower ends of casing 25 and 27 arepositioned against trim guide poles 141 and 215.

Air cylinders 404 and 412 of air cylinder assemblies 380 and 382,respectively, of 1) clamping assemblies 132 and combined stapling andclamping units 149 of fixed bank 24 and 2) clamping assemblies 198 andcombined stapling and clamping assemblies 213 of movable bank 26 areactivated and extend plungers 406 and 414 into engagement with sidecasing 25 and 27 (see FIGS. 9 and 36C). Plungers 406 and 414 retain sidecasing 25 and 27 in abutment with protective material 162.

Next, air cylinders 189 and 197 of air cylinder assemblies 183 and 185are activated to retract plungers 191 and 199, respectively, thusretracting movable bank 26 to its outermost position (see FIG. 36C).

Air cylinders 350 of air cylinder assemblies 336, 338, 340 and 342 arethen activated and push plungers 352 of the air cylinder assembliesupward. Plungers 352 push cross beam assemblies 344 and 346 upward untilthey engage the bottom of door frame assembly 21. Further elevation ofthe plungers 352 causes cross beam assemblies 344 and 346 to lift doorframe assembly 21 off of conveyor belt assembly 36 and into a positionadjacent and of the same elevation as jamb locators 134 and 194 of fixedbank of stapling units and movable bank of stapling units 26,respectively (see FIG. 36C). One longitudinal edge of door frameassembly 21 is adjacent jamb locator 134. Air cylinder assemblies 336,338, 340 and 342 maintain cross beam assemblies 344 and 346, and thusdoor frame assembly 21, at this elevation while casing is attached toone side of the door frame assembly 21.

Next, air cylinders 189 and 197 of air cylinder assemblies 183 and 185,respectively, are activated, and extend plungers 191 and 199,respectively, inwardly. This movement pushes slidable frame assembly 182inward until jamb locator 134 is in abutment with one longitudinal edgeof door frame assembly 21 and jamb locator 194 is in abutment with theother longitudinal edge of door frame assembly 21 (see FIG. 36D). Aircylinder 428 of air cylinder assembly 225 is activated, and causesplunger 430 to extend and engage adjacent teeth 121 of spacer bar 111(see FIG. 16). This locks slidable frame 182 relative bottom supportframe assembly 22.

Air cylinder 442 of air cylinder assembly 434 of clamping assembly 244is activated, driving plunger 444 firmly against slide block 436, whichin turn drives slide block 436 firmly against pivot bar 236 (see FIG.21). This locks clamping assembly 244 relative pivot bar 236.

Next, head casing 23 is inserted into channel brackets 312 of clampingassemblies 242 (see FIGS. 19 and 36D). Head casing 23 is received fromglue applying station 530 via chute 532. Head casing 23 has glue appliedon the under side of its leading edge. Head casing 23 is placed with itsbottom surface against the top surface of protective material 318 andthe back edge against the back wall of protective material 318. Theright edge of head casing 23 is placed in abutment with plunger 476 ofair cylinder assembly 468 of trim guide assembly 247, which is in itsextended position, extending through and below pole 466 (see FIG. 17).Air cylinders 324 of air cylinder assemblies 316 of clamping assemblies242 and 244 are activated and extend plungers 326 down into engagementwith head casing 23, retaining head casing 23 in channel brackets 312(see FIG. 19).

Air cylinders 179 of lower air cylinder assembly 140 of fixed bank 24and of lower air cylinder assembly 204 of movable bank 26 are activatedand drive the respective plungers 180 against the ends of the side jambsof door frame assembly 21 (see FIG. 13). This movement moves door frameassembly 21 against the plungers 325 of air cylinder assemblies 243 and245 of head bank 28 so that door frame assembly 21 is properly alignedlongitudinally relative casing attachment machine 20 (see FIG. 17).

Air cylinder 133 of air cylinder assembly 129 of fixed bank 24, aircylinder 205 of air cylinder assembly 181 of movable bank 26 and aircylinder 480 of air cylinder assembly 249 of head bank 28 are activated,extending plungers 135, 207 and 482, respectively. Since the free endsof extendable rods 135, 207 and 482 are rotatably attached to gussetplates 137, 209 and 484, which are in turn fixedly attached to pivotbars 128, 188 and 236, the extension of extendable rods 135, 207 and 482causes pivot bars 128, 188 and 236 to rotate inwardly, respectively (seeFIGS. 4, 15 and 24).

This rotation causes 1) stapling units 130, clamping assemblies 132 andcombined stapling and clamping units 149 of fixed bank 24, 2) staplingunits 196, clamping assemblies 198 and combined stapling and clampingunits 213 of movable bank 26 and 3) clamping assemblies 242 and 244 andmovable stapling unit assembly 238 of head bank 28 to be rotated fromtheir respective raised positions to their respective lowered positions(see FIG. 36E). In these lowered positions, since casing 23, 25 and 27is positioned in the channel brackets 160 of clamping assemblies 132 and198 and combined stapling and clamping units 149 and 213 and the channelbrackets 312 of clamping assemblies 242 and 244, casing 23, 25 and 27 ispositioned in abutment with the jambs of door frame assembly 21 (see,for example, FIG. 22). Note that staplers 152 are still above therespective casing 23, 25 and 27.

With regard to clamping assembly 242, the rotation of pivot bar 236pushes arm 308 inward since arm 308 is rotatably attached on one end topivot bar 236 by gusset plate 306 (see FIGS. 18 and 23). The other endof arm 308 is rotatably attached to bracket 310. The axis of rotation ofarm 308 relative bracket 310 is spaced from the axis of rotation ofbracket 310. Bracket 310 is attached to and thus rotatable withsecondary pivot bar 276. Thus, movement of arm 308 causes rotation ofbracket 310 about secondary pivot bar 276. The rotation of bracket 310rotates channel bracket 312, L-shaped bracket 314 and air cylinderassembly 316 to their respective down positions.

With respect to clamping assembly 244, collar 432 is attached to pivotbar 236, and thus rotates with pivot bar 236. Arm 438 and 440 areconnected, end-to-end, between collar 432 and bracket 310 of clampingassembly 244. Rotation of collar 432 causes movement of arms 438 and 440inward, thus rotating bracket 310 and secondary pivot bar 276, asdiscussed above with respect to clamping assembly 242 (see FIG. 21).

Air cylinders 178 of upper air cylinder assembly 138 of fixed bank 24and of upper air cylinder assembly 202 of movable bank 26 are activatedto extend the respective plungers 180 inwardly to properly locate casing25 and 27, longitudinally, relative door frame assembly 21 (see FIG.13).

Air cylinders 279 of air cylinder assemblies 264 of corner splicingassemblies 30 and 32 are activated, extending plungers 281 downward (seeFIGS. 27A and 27B). This movement of plungers 281 downward causes links488 and 490 to slide head assemblies 251 forward to the innermostposition of head assemblies 251. The top ends of casing 25 and 27 andboth ends of casing 23 are received on casing support plates 252,against surfaces 263 and 265 of spline guides 254 and 256 of cornersplicing assemblies 30 and 32 (see FIG. 26).

Next, air cylinders 166 of air cylinder assemblies 164 of clampingassemblies 132 and combined stapling and clamping units 149 of fixedbank 24 and of clamping assemblies 198 and combined stapling andclamping units 213 of movable bank 26 are activated, extending plungers168. Likewise, air cylinders 321 of air cylinder assemblies 319 ofclamping assemblies 242 and 244 of head bank 28 are activated, pushingplungers 327 outward. This further secures casing 23, 25 and 27 againstthe appropriate jambs since plungers 168 and 327 are connected toL-shaped brackets 158 and 314, respectively, and thus apply rotationalforce on channel brackets 160 and 312, pressing casing 23, 25 and 27against the jambs of door frame assembly 21 (see FIGS. 9, 17-19 and 21).This movement results in a cam action which forces any excess glue outthe back edge of casing 23, 25 and 27.

In addition, to further secure casing 23, 25 and 27 in abutment withdoor frame assembly 21 and to secure the mitered edges of casing 23, 25and 27 in abutment, air cylinders 494 of air cylinder assemblies 328 ofcorner splicing assemblies 30 and 32 are activated, rotating clampassembly 330 to the down position such that rubber tips 334 engage thecorners of the respective casing pieces, one rubber tip 334 beingpositioned on each side of the miter between the respective pieces (seeFIGS. 29 and 30). This is accomplished since air cylinders 494 pushplungers 500 outward. This causes the rotation of links 506, brackets510 and arms 512 about brackets 504, as discussed above.

Air cylinders 180 of top air cylinder assemblies 170 and 204 of fixedbank 24 and movable bank 26 are activated, withdrawing the respectiveplungers 178 out of contact with the casing (see FIG. 13). Next, aircylinders 155 of 1) air cylinder assemblies 153 of stapling unitassemblies 130 and combined stapling and clamping units 149 of fixedbank 24 and 2) stapling unit assemblies 196 and combined stapling andclamping units 213 of are activated, withdrawing the respective plungers157 (see FIG. 5). Since plungers 157 are rotatably attached to staplers152, this causes rotation of staplers 152 to the position wherein anvils154 are in abutment with the appropriate casing pieces (see FIG. 36F).Likewise, air cylinders 460 of air cylinder assemblies 452 of stationarystapling units 233 of head bank 28 are activated, withdrawing plungers462 and rotating staplers 446 such that anvils 285 are in contact withhead casing 27 (see FIG. 22).

Staplers 152 of 1) stapling unit assemblies 130 and combined staplingand clamping units 149 of fixed bank 24, and 2) stapling unit assemblies196 and combined stapling and clamping units 213 of movable bank 26 andstaplers 446 of stationary stapling assemblies 233 and 235 of head bank28 are simultaneously activated, driving staples through casing 23, 25and 27 into the jambs of door frame assembly 21 to secure casing 23, 25and 27 to the door frame assembly 21.

Next, linear staple unit drive assembly 240 and movable stapling unitassembly 238 are activated and function co-jointly. These units worksuch that linear drive motor 246 is activated to extend plunger 248 withperiodic stops at selected spaced intervals (see FIG. 34). Since movablestapling unit assembly 238 is attached to plunger 248, it likewise movesand stops periodically at the selected spaced intervals. Wheneverstapling unit assembly 238 stops, it is activated to drive a staple intocasing 23 and door frame assembly 21.

Specifically, when movable stapling unit assembly 238 stops, aircylinder 293 of air cylinder assembly 291 is activated, driving theplunger thereof into firm engagement with slide blocks 298, which inturn firmly engages pivot bar 236 (see FIG. 18). This "locks" movablestapling unit assembly 238 relative pivot bar 236. Air cylinder 296 ofair cylinder assembly 289 is operated to retract plunger 298, pullingstapler 284 down such that anvil 285 abuts head casing 23. Stapler 284is activated, driving a staple through head casing 23 into theunderlying jamb. Air cylinder assembly 289 is activated, pushing plunger298 upward against stop 286 and rotating stapler 284 away from headcasing 23. Air cylinder 293 is activated to retract its plunger. Thispermits movable stapling unit assembly 238 to slide along pivot bar 238.The motor of linear staple unit drive assembly 240 is activated,extending plunger 248. Plunger 248 stops at a pre-programmed distance.

At this point, the above sequence regarding air cylinder assemblies 291and 289 and stapler 284 is repeated, driving another staple into headcasing 23 and the appropriate jamb. When movable stapling unit assembly238 has traversed the width of door frame assembly 21, plunger 248 iscompletely retracted, returning movable stapling unit assembly 238 toits starting position.

In this manner, staples are driven along head casing 23 and atpredetermined intervals, regardless of the width of the door frameassembly being worked upon. This feature enables casing attachmentmachine 20 to accept and attach casing to door frame assemblies ofvarious widths.

Next, air cylinders 155 of air cylinder assemblies 153 of stapling unitassemblies 130 and combined stapling and clamping units 149 of fixedbank 24 and of stapling unit assemblies 196 and combined stapling andclamping units 213 of movable bank 26 are activated, extending plungers157, and thus pushing top arms 370 of Z-bars 151 upward (see FIG. 5).This rotates staplers 152 upward away from the casing. Likewise, aircylinders 460 of air cylinder assemblies 452 of stationary staplingunits 233 and 235 are activated, retracting plungers 462 and rotatingstaplers 446 upward away from the casing (see FIG. 22).

Next, air cylinders 273 of air cylinder assemblies 260 of cornersplicing assemblies 30 and 32 are activated, driving plungers 261outward (see FIGS. 27A and 27B). Since plungers 261 are connected todrivers 258 and splines 29 have been inserted into the channels betweenspline guides 254 and 256, in front of drivers 258, splines 29 aredriven into the casing corners by plungers 261 and drivers 258. Aircylinders 273 are then activated to retract plungers 261 and drivers258. Air cylinders 494 of air cylinder assemblies 328 of clampingassemblies 267 are then activated to unclamp the casing corners (seeFIGS. 29 and 30). Specifically, plungers 500 of air cylinder assemblies328 are retracted, causing the rotation of links 506, brackets 510 andarms 512 about brackets 504, as discussed above.

Air cylinders 178 of lower air cylinder assemblies 140 and 204 of fixedbank 24 and head bank 26, respectively, are activated to retract therespective plungers 180 out of engagement with door frame assembly 21(see FIG. 13).

Air cylinders 166 of air cylinder assemblies 164 of clamping assemblies132 and combined stapling and clamping units 149 of fixed bank 24 and ofclamping assemblies 198 and combined clamping and stapling units 213 ofmovable bank 26 are activated, retracting plungers 168 (see FIG. 9). Aircylinders 321 of air cylinder assemblies 319 of clamping assemblies 242and 244 of head bank 28 are operated to retract plungers 327 (see FIGS.17-19). This releases some of the pressure on casing 23, 25 and 27.

Air cylinders 279 of air cylinder assemblies 264 of corner splicingassemblies 30 and 32 are operated to retract plungers 281. This causeshead assembly 251 to slide outwardly to its starting position (see FIGS.27A and 27B).

Air cylinders 404 of air cylinder assemblies 380 and air cylinders 412of air cylinder assemblies 382, both of 1) clamping assemblies 132 andcombined stapling and clamping units 149 of fixed bank 24 and 2)clamping assemblies 198 and combined stapling and clamping assemblies213 of movable bank 26 are activated to withdraw plungers 406 and 414out of contact with casing 25 and 27 (see FIG. 9). Likewise, aircylinders 324 of air cylinder assemblies 316 of clamping assemblies 242and 244 are activated to withdraw plungers 326 out of contact with headcasing 23 (see FIG. 19).

Air cylinders 189 and 197 of air cylinder assemblies 183 and 185 areactivated, retracting plungers 191 and 199, respectively, and thusretracting movable bank 26 to its outermost position.

Air cylinders 323 of ejection air cylinder assemblies 243 and 245 ofhead bank 28 are activated to extend and retract plungers 325 (see FIG.18). The extension of plungers 325 pushes the entire door frame assembly21 away from head bank 28.

Air cylinder 442 of air cylinder assembly 434 of head bank 28 isactivated to retract plunger 444, such that side blocks 436, and thusthe entire clamping assembly 244, are free to slide relative pivot bar236 (see FIG. 21). Air cylinder 428 of air cylinder lock assembly 225 isactivated to retract plunger 430 out of engagement with teeth 121 ofspacer bar 111 (see FIG. 16). This frees slidable frame assembly 182 sothat it can slide relative bottom support frame assembly 22.

Air cylinders 536 of air cylinder assemblies 177 and 179 of fixed bank24 are activated, extending plungers 538 and stops 540 inwardly (seeFIG. 35). This movement pushes the door frame assembly away from jamblocator 134 at least a distance such that casing 25 is out of channelbrackets 160 of clamping assemblies 132 and combined stapling andclamping units 149. Plungers 538 are then retracted to their startpositions.

Air cylinders 350 of air cylinder assemblies 336, 338, 340 and 342 areactivated to lower plungers 352, and thus cross beam assemblies 344 and346 and the entire door frame assembly. This movement is continued untilcross beam assemblies 340 and 342 are beneath the top surface of theconveyor belt of conveyor belt assembly 36 such that the door frameassembly is replaced on conveyor belt assembly 36.

Air cylinders 133, 205 and 480 of air cylinder assemblies 129, 181 and249 are activated to retract plungers 135, 207 and 482, and thus rotatepivot bars 128, 188 and 236, respectively, back to their startingposition (see FIGS. 4, 15 and 24). This rotates all of the staplingunits 130, 196, 233, 235 and 238, clamping assemblies 132, 198, 242 and244 and combined stapling and clamping units 149 and 213 upwardly.

Air cylinders 189 and 197 are activated to extend plungers 191 and 199,respectively. This moves movable bank 26 back towards fixed bank 24until movable bank 26 reaches its starting position.

Conveyor belt assembly 36 is then activated and transmits door frameassembly 21, now having casing attached on one side, to conveyor 520(see FIG. 33). Conveyor 520 transports door frame assembly 21 to doorturning station 522. After door frame assembly 21 is rotated 180 degreesat door turning station 522, either by hand or automatically, door frameassembly 21 is transported by conveyor 524 to the second casingattaching machine 20, wherein the above steps are repeated to attachcasing to the second side of door frame assembly 21, with one exception.

The sole exception is that when the door frame assembly is received oncross beam assemblies 344 and 346, the appropriate air cylinderassemblies 347 are activated to raise the appropriate support squares345 such that the jambs are supported by the appropriate support squares345 (see FIG. 32). The support squares 345 which are raised aredependent on the width of the door frame assembly being worked on.

After casing is attached to the second side of door frame assembly 21 bythe second casing attachment machine 20, conveyor 526 transports thecompleted door frame assembly to output station 528.

Programmable logic controller 38 is programmed to automatically sequencethe various elements of the assembly line and casing attachment machines20 as discussed above. All of the air cylinder valves and manifolds areregulated by programmable logic controller 38 to release air to thevarious air cylinders to perform the steps stated above.

In addition, the various stapling units of casing attachment machine 20can be oriented at various angles with respect to casing received incasing attachment machine 20. In this manner, the staples can be drivenin with the grain, across the grain or at any desired angle with thegrain.

Other improvements, embodiments and modifications to this invention willbecome apparent to those skilled in the art once given this disclosure.Such other embodiments, improvements and modifications are considered tobe within the scope of the claims as set forth below.

I claim:
 1. A machine for attaching casing to a structural frameassembly, said machine comprising:a support frame assembly; a fixed bankof stapling units supported by said support frame assembly, said fixedbank includinga fixed bank pivot bar rotatably supported by said supportframe assembly, at least one fixed bank stapling unit, attached to saidfixed bank pivot bar, for driving staples to attach said casing to saidstructural frame assembly, fixed bank clamping means for clamping saidcasing adjacent said structural frame assembly during the stapling ofsaid casing to said structural frame assembly, said fixed bank clampingmeans being attached to said fixed bank pivot bar, and a fixed bank jamblocator fixedly supported by said support frame assembly; a movable bankof stapling units spaced from and oriented substantially parallel tosaid fixed bank of stapling units and includingsupport bars slidablysupported by said support frame assembly, a movable bank pivot barrotatably supported by said support bars, a movable bank jamb locatorfixedly supported by said support bars, at least one movable bankstapling unit, attached to said movable bank pivot bar, for drivingstaples to attach said casing to said structural frame assembly, movablebank clamping means for clamping said casing adjacent said structuralframe assembly during the stapling of said casing to said structuralframe assembly, said movable bank clamping means being attached to saidmovable bank pivot bar, and means for reciprocally sliding said supportbars relative said support frame assembly; a head bank of stapling unitslocated at one end of said fixed and movable banks of stapling units andincludinga head bank pivot bar rotatably supported by said support frameassembly, a head bank stapling unit, attached to said head bank pivotbar, for driving staples to attach said casing to said structural frameassembly, and head bank clamping means for clamping said casing adjacentsaid structural frame assembly during the stapling of said casing tosaid structural frame assembly, said head bank clamping means beingattached to said head bank pivot bar; and means for controlling andactivating said sliding means of said movable bank, all of said staplingunits and all of said clamping means;wherein said jamb locators aredesigned and positioned to receive and engage the structural frameassembly.
 2. A machine for attaching casing to a structural frameassembly in accordance with claim 1, further comprising:means attachedto said support frame assembly and said movable bank to lock saidmovable bank in a plurality of positions relative said support frame. 3.A machine for attaching casing to a structural frame assembly inaccordance with claim 1, whereinsaid fixed bank, said movable bank andsaid head bank each include means for rotating said pivot bars; saidmeans for rotating said fixed bank and head bank pivot bars beingattached to said support frame assembly and said fixed bank and headbank pivot bars, respectively; said means for rotating said movable bankpivot bar being attached to said support bars and said movable bankpivot bar.
 4. A machine for attaching casing to a structural frameassembly in accordance with claim 1, whereinall of said stapling unitsinclude means for rotating said stapling units relative said pivot bars.5. A machine for attaching casing to a structural frame assembly inaccordance with claim 1, whereinsaid fixed bank and movable bankstapling units each include a Z-bar, a stapler and means for rotatingsaid Z-bar and stapler relative said pivot bars, said Z-bar having topand bottom arms substantially in parallel and a cross bar extendingdiagonally between said top and bottom arms; said bottom arm of saidZ-bar being rotatably attached to said pivot bar; said stapler beingattached to said cross bar of said Z-bar.
 6. A machine for attachingcasing to a structural frame assembly in accordance with claim 5,whereinsaid means for rotating said Z-bar and stapler relative saidpivot bars includes an air cylinder assembly extending between and beingattached to said pivot bar and said top arm of said Z-bar.
 7. A machinefor attaching casing to a structural frame assembly in accordance withclaim 6, whereinsaid fixed and movable banks include a plurality of saidfixed bank and movable bank stapling units spaced along said fixed andmovable banks.
 8. A machine for attaching casing to a structural frameassembly in accordance with claim 1, whereineach of said fixed bank,movable bank and head bank clamping means include a clamping unitcomprising a support bracket, a channel bracket, and means for rotatingsaid support bracket and said channel bracket relative said pivot bars;said support bracket being rotatably attached to one of said pivot bars;said channel bracket being attached to said support bracket and being ofa size and shape to receive casing therein.
 9. A machine for attachingcasing to a structural frame assembly in accordance with claim 8,whereinsaid means for rotating said support bracket and said channelbracket includes a first air cylinder assembly extending between andbeing connected to one of said pivot bars and said support bracket, theconnection of the first air cylinder assembly to the support bracketbeing spaced from the connection of the support bracket to one of thepivot bars.
 10. A machine for attaching casing to a structural frameassembly in accordance with claim 9, whereinsaid clamping units of saidfixed bank, movable bank and head bank clamping means each include asecond air cylinder assembly, said second air cylinder assembly beingattached to said support bracket and having an extendable andretractable plunger designed to engage casing received in said channelbracket when said plunger is in an extended position.
 11. A machine forattaching casing to a structural frame assembly in accordance with claim10, whereinsaid fixed, movable and head banks comprise a plurality ofspaced said clamping units.
 12. A machine for attaching casing to astructural frame assembly according to claim 11, whereinsaid clampingunits have at least an up and a down position, said clamping units beingdesigned to receive casing in said channel brackets when in the upposition and to position said casing in said channel brackets adjacentthe structural door frame assembly positioned in the machine when in thedown position.
 13. A machine for attaching casing to a structural frameassembly according to claim 1 whereinsaid head bank includes a secondarypivot bar and arms connecting said secondary pivot bar with said headbank pivot bar such that said secondary pivot bar rotates when said headbank pivot bar rotates, said head bank clamping means being attached tosaid secondary pivot bar.
 14. A machine for attaching casing to astructural frame assembly according to claim 13, whereinsaid armsconnecting said head bank pivot bar and said secondary pivot bar includea U-bracket and elongated arms; said elongated arms being attached tosaid head bank pivot bar on one end and to said U-bracket at the otherend, said U-bracket being attached to said secondary pivot bar, saidclamping means being attached to said U-bracket; the connection of saidU-bracket to said secondary pivot bar is between the connections of theU-bracket to said elongated arms and said clamping means.
 15. A machinefor attaching casing to a structural frame assembly according to claim14, whereinsaid head bank stapling unit is slidably supported by saidhead bank pivot bar.
 16. A machine for attaching casing to a structuralframe assembly according to claim 15, whereinsaid controlling meansoperates to move and activate said head bank stapling unit at fixedintervals along said head bank pivot bar.
 17. A machine for attachingcasing to a structural frame assembly according to claim 16, whereinsaidhead bank includes an additional stapling unit attached to saidsecondary pivot bar.
 18. A machine for attaching casing to a structuralframe assembly according to claim 1, whereinsaid head bank stapling unitis slidably supported by said head bank pivot bar.
 19. A machine forattaching casing to a structural frame assembly according to claim 1,further comprising:first splicing means for driving a spline intocasing, said first splicing means being located at the corner formed bysaid fixed bank and said head bank and being supported by said supportassembly; and second splicing means for driving a spline into casing,said second splicing means being located at the corner formed by saidmovable bank and said head bank and being supported by said supportbars.
 20. A machine for attaching casing to a structural frame assemblyaccording to claim 19, whereinsaid first and second splicing means eachinclude a head, a clamp assembly and means for driving a spline; saidhead being designed to engage a corner of casing placed in the machine,said clamp assembly being designed to clamp the casing in said head andsaid driving means being designed to drive a spline into the casing. 21.A machine for attaching casing to a structural frame assembly accordingto claim 1, further comprising:means for moving and positioning thestructural frame assembly from outside the machine to a positionadjacent said fixed bank and for moving the structural frame assemblyaway from said fixed bank.
 22. A machine for attaching casing to astructural frame assembly according to claim 21, whereinsaid moving andpositioning means includes a conveyor assembly and means for lifting andlowering the structural frame assembly.
 23. A machine for attachingcasing to a structural frame assembly according to claim 22, whereinsaidconveyor system is located within said support frame assembly below allof said jamb locators and said lifting and lowering means lifts thestructural frame assembly from said conveyor system to a positionadjacent said fixed bank jamb locator and lowers the structural frameassembly from the position adjacent the fixed bank jamb locator to theconveyor assembly.
 24. A machine for attaching casing to a structuralframe assembly according to claim 1 whereinsaid fixed bank and saidmovable bank of stapling units each include a first end adjacent saidhead bank of stapling units and a second end, said fixed bank and saidmovable bank of stapling units each include end positioning units, saidend positioning units being located at said second ends of said fixedbank and said movable bank of stapling units, said end positioningunits 1) engaging the casing when the casing is in abutment with thestructural frame assembly and 2) aligning the casing relative thestructural frame assembly.
 25. A machine for attaching casing to astructural frame assembly according to claim 24, whereinsaid endpositioning units each include top and bottom extendable and retractablearms, said arms being oriented substantially parallel to said jamblocators, said top arms being positioned to engage said casing and saidbottom arms being positioned to engage said structural frame assemblywhen said casing is properly in abutment with said structural frameassembly.
 26. A machine for attaching casing to a structural frameassembly according to claim 1, whereinsaid movable bank stapling unitsare aligned along a first straight line and said fixed bank staplingunits are aligned along a second straight line, said first and saidsecond straight lines being substantially parallel.
 27. A machine forattaching casing to a structural frame assembly according to claim 1,whereinsaid fixed bank and movable bank jamb locators are elongatedrods, said machine having a longitudinal axis, said fixed bank andmovable bank jamb locators being oriented substantially parallel to saidlongitudinal axis.
 28. A machine for attaching casing to a structuralframe assembly according to claim 27, whereinsaid jamb locators includean interior flat surface for abutment with the structural frameassembly.
 29. A machine for attaching casing to a structural frameassembly according to claim 1, whereinsaid machine has a longitudinalaxis, said movable bank of stapling units being movable in a directionsubstantially perpendicular to said longitudinal axis.
 30. An assemblyfor attaching casing to a structural frame assembly comprising:aconveyor belt assembly; two machines for attaching casing to one side ofthe structural frame assembly, each of said machines comprising: asupport frame assembly; a fixed bank of stapling units supported by saidsupport frame assembly, said fixed bank includinga fixed bank pivot barrotatably supported by said support frame assembly, at least one fixedbank stapling unit, attached to said fixed bank pivot bar, for drivingstaples to attach said casing to said structural frame assembly, fixedbank clamping means for clamping said casing adjacent said structuralframe assembly during the stapling of said casing to said structuralframe assembly, said fixed bank clamping means being attached to saidfixed bank pivot bar, and a fixed bank jamb locator fixedly supported bysaid support frame assembly; a movable bank of stapling units orientedsubstantially parallel to said fixed bank of stapling units andincludingsupport bars slidably supported by said support frame assembly,a movable bank pivot bar rotatably supported by said support bars, amovable bank jamb locator fixedly supported by said support bars, atleast one movable bank stapling unit, attached to said movable bankpivot bar, for driving staples to attach said casing to said structuralframe assembly, movable bank clamping means for clamping said casingadjacent said structural frame assembly during the stapling of saidcasing to said structural frame assembly, said movable bank clampingmeans being attached to said movable bank pivot bar, and means forreciprocally sliding said support bars relative said support frameassembly; a head bank of stapling units located at one end of said fixedand movable banks of stapling units and includinga head bank pivot barrotatably supported by said support frame assembly, a head bank staplingunit, attached to said head bank pivot bar, for driving staples toattach said casing to the structural frame assembly, and head bankclamping means for clamping said casing adjacent the structural frameassembly during the stapling of said casing to said structural frameassembly, said head bank clamping means being attached to said head bankpivot bar; corner splicing assemblies located at corners formed by (1)said fixed bank and said head bank and (2) said movable bank and saidhead bank; means for moving said structural frame assembly from saidconveyor belt assembly, positioning said frame assembly adjacent saidfixed bank, moving said structural frame assembly away from said fixedbank and returning said structural frame assembly to said conveyorassembly; and means for controlling and activating said sliding means ofsaid movable bank, said stapling units and said clamping means;whereinsaid jamb locators are designed to receive and engage the structuralframe assembly; and a frame assembly turning station; wherein saidconveyor belt assembly, said two machines for attaching casing to oneside of the structural frame assembly and said frame assembly turningstation are arranged such that the structural frame assembly istransported by the conveyor assembly from a first of the machines forattaching casing, to the frame assembly turning station to the second ofthe machines for attaching casing.
 31. A machine for forming astructural member from various individual members comprising:a supportframe assembly; a fixed bank of stapling units supported by said supportframe assembly, said fixed bank includinga fixed bank pivot barrotatably supported by said support frame assembly, and at least onefixed bank stapling unit, attached to said fixed bank pivot bar, fordriving staples to attach at least first and second members of thevarious individual members; a movable bank of stapling units spaced fromand oriented substantially parallel to said fixed bank of stapling unitsand includingmeans for moving said movable bank between in and outpositions, said moving means being supported by said support frameassembly, a movable bank pivot bar, and at least one movable bankstapling unit, attached to said movable bank pivot bar, for drivingstaples to attach at least third and fourth members of the variousindividual members; a head bank of stapling units located at one end ofsaid fixed and movable banks of stapling units and including a head bankpivot bar rotatably supported by said support frame assembly, anda headbank stapling unit, attached to said head bank pivot bar, for drivingstaples to attach at least fifth and sixth members of said individualmembers; and means for controlling and activating said movable bank andsaid stapling units.
 32. A machine for forming a structural member fromvarious individual members in accordance with claim 31, whereinsaidfixed bank of stapling units includes fixed bank clamping means forclamping said first member adjacent said second member during thestapling of said first member to said second member, said fixed bankclamping means being attached to said fixed bank pivot bar; said movablebank of stapling units includes movable bank clamping means for clampingsaid third member adjacent said fourth member during the stapling ofsaid third member to said fourth member, said movable bank clampingmeans being attached to said movable bank pivot bar; and said head bankof stapling units includes head bank clamping means for clamping saidfifth member adjacent said sixth member during the stapling of saidfifth member to said sixth member, said head bank clamping means beingattached to said head bank pivot bar; and further comprising means forcontrolling and activating all of said clamping means.
 33. A machine forforming a structural member from various individual members inaccordance with claim 32, whereineach of said fixed bank, movable bankand head bank clamping means include a clamping unit comprising asupport bracket, a channel bracket, and means for rotating said supportbracket and said channel bracket relative said pivot bars; said supportbracket being rotatably attached to one of said pivot bars; said channelbracket being attached to said support bracket and being of a size andshape to receive certain of said individual members therein.
 34. Amachine for forming a structural member from various individual membersin accordance with claim 33, whereinsaid means for rotating said supportbracket and said channel bracket includes a first air cylinder assemblyextending between and being connected to one of said pivot bars and saidsupport bracket, the connection of the first air cylinder assembly tothe support bracket being spaced from the connection of the supportbracket to one of the pivot bars.
 35. A machine for forming a structuralmember from various individual members in accordance with claim 34,whereinsaid clamping units of said fixed bank, movable bank and headbank clamping means each include a second air cylinder assembly, saidsecond air cylinder assembly being attached to said support bracket andhaving an extendable and retractable plunger designed to engage saidindividual members received in said channel bracket when said plunger isin an extended position.
 36. A machine for forming a structural memberfrom various individual members in accordance with claim 31, whereinsaidmeans for moving said movable bank comprises support bars slidablysupported by said support frame assembly and means for reciprocallysliding said support bars relative said support frame assembly.
 37. Amachine for forming a structural member from various individual membersin accordance with claim 32, further comprisingmeans attached to saidsupport frame assembly and said movable bank to lock said movable bankin a plurality of positions relative said support frame assembly.
 38. Amachine for forming a structural member from various individual membersin accordance with claim 32, whereinsaid head bank includes a secondarypivot bar and arms connecting said secondary pivot bar with said headbank pivot bar such that said secondary pivot bar rotates when said headbank pivot bar rotates, said head bank clamping means being attached tosaid secondary pivot bar.
 39. A machine for forming a structural memberfrom various individual members in accordance with claim 32, whereinsaidfixed bank, said movable bank and said head bank each include means forrotating said pivot bars; said means for rotating said fixed bank andhead bank pivot bars being attached to said support frame assembly andsaid fixed bank and head bank pivot bars, respectively; said means forrotating said movable bank pivot bar being attached to said support barsand said movable bank pivot bar.
 40. A machine for forming a structuralmember from various individual members in accordance with claim 32,whereinall of said stapling units include means for rotating saidstapling units relative said pivot bars.
 41. A machine for forming astructural member from various individual members in accordance withclaim 40, whereinsaid fixed bank and movable bank stapling units eachinclude a Z-bar, a stapler and means for rotating said Z-bar and staplerrelative said pivot bars, said Z-bar having top and bottom armssubstantially in parallel and a cross bar extending diagonally betweensaid top and bottom arms; said bottom arm of said Z-bar being rotatablyattached to said pivot bar; said stapler being attached to said crossbar of said Z-bar.
 42. A machine for forming a structural member fromvarious individual members in accordance with claim 32, whereinsaid headbank stapling unit is slidably supported by said head bank pivot bar.43. A machine for forming a structural member from various individualmembers in accordance with claim 42,said controlling means operates tomove and activate said head bank stapling unit at fixed intervals alongsaid head bank pivot bar.